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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 14 Mar 2022 15:24 #863798

  • Mikaw
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Moving on   LOL, 

I bought these hoping the clamp them on the axle clamp stud to remove them without maring them up, so that I can blast the lowers without ruining the studs. Worked good. 


 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 14 Mar 2022 15:26 #863799

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Moving on   LOL, 

I bought these hoping the clamp them on the axle clamp stud to remove them without maring them up, so that I can blast the lowers without ruining the studs. Worked good.
 

That's a good idea!
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 14 Mar 2022 15:29 #863800

  • Forrest
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two nuts are better than one...!
 

Yes, Yes they are.  
KZ RIDER RELAY FLAG CARRIER #55
1977 KZ650B Ready & Fit to Roll Anywhere!
1974 F7 175 -first bike and still own, full resto soon!
2002 ZRX1200R -Red the faster color
2011 Concours 14 -Now a Snarling Wolf in Sheep's Clothing!

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 14 Mar 2022 15:37 #863802

  • Forrest
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Boy Oh Boy, have I been getting an education not only from The Collective here but searching online.  It started with tap & die tools search.  Next thing I know I am looking at special "Stud Removal Sockets"!  Here is the link.>>>    BikeMaster Stud Removal Sockets | 10% ($4.88) Off! - RevZilla   

I ordered a set.  If I have not got that out by the time they arrive, then they are up next.  One thing is for sure.  I am adding to my tools as I go.    
KZ RIDER RELAY FLAG CARRIER #55
1977 KZ650B Ready & Fit to Roll Anywhere!
1974 F7 175 -first bike and still own, full resto soon!
2002 ZRX1200R -Red the faster color
2011 Concours 14 -Now a Snarling Wolf in Sheep's Clothing!

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 14 Mar 2022 16:10 #863803

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Hi Forrest, these sockets work well (I have a set) but a word of warning, make sure you‘ve done your heat and penetrating fluid because they grip like a “lady of the night” on your wallet so feel that stud out gently 

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 15 Mar 2022 09:44 #863829

  • Forrest
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Hi Forrest, these sockets work well (I have a set) but a word of warning, make sure you‘ve done your heat and penetrating fluid because they grip like a “lady of the night” on your wallet so feel that stud out gently 
Copy That Wookie.  BTW, love the analogy.  
Applied more heat this a.m. along with a mallet impact tap then shot it with more penetrating oil.  "Treating her gently like the first time", not like a "lady of the night".  

Just to be sure; thee pinch bolt stud threads up in the fork are standard thread NOT reverse thread, Right?
KZ RIDER RELAY FLAG CARRIER #55
1977 KZ650B Ready & Fit to Roll Anywhere!
1974 F7 175 -first bike and still own, full resto soon!
2002 ZRX1200R -Red the faster color
2011 Concours 14 -Now a Snarling Wolf in Sheep's Clothing!

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 15 Mar 2022 10:24 #863831

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I don’t know for sure but I can’t imagine they would be reverse. In the automotive world this is normally only on rotating parts like hubs or “centre lock” wheels to stop them working loose - be gentle and she will love you forever 
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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 15 Mar 2022 15:06 #863838

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Righty Tighty!
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 16 Mar 2022 13:53 #863874

  • Forrest
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Righty Tighty!
Roger Dodger! 

 
KZ RIDER RELAY FLAG CARRIER #55
1977 KZ650B Ready & Fit to Roll Anywhere!
1974 F7 175 -first bike and still own, full resto soon!
2002 ZRX1200R -Red the faster color
2011 Concours 14 -Now a Snarling Wolf in Sheep's Clothing!

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 29 Mar 2022 10:58 #864482

  • Forrest
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UPDATE:  In the past two weeks, I have heated, shot with penetrating oil, double nutted, Tried the 8mm Stud Removal socket.  BTW,  stud removal socket worked on the non broken stud just fine.  I have steadily gone down a rabbit hole on this situation.  When trying the Stud Removal Socket, the locking roller cams inside would slip.  This was due to me wearing away the stud diameter to where it is less than 8mm.  My next attempt was to re thread the stud to 7mm.  Used 7mm x 1.0 thread.  Not as easy to find 7mm x 1.0 nuts and such but did.  Again, heating & penetrating oil applied between attempts.  Got the double nut to hold but could not budge.  Did not weld the nut due to no welding equipment or experience.  Went to reposition/replace nuts and then discovered the threads were damaged and would not hold.  So, I got the bright idea to see if the 6mm Stud Removal Socket would fit over the stripped down stud.  YES! It slipped down onto the stud, fitting very snug.  Now with added confidence of knowing I have removed the other non broken stud fairly easily, I turned with a bit more power and... I snapped off almost all of the remaining exposed stud.  I know that if I would have simply been thinking straight from the moment I initially over torqued and snapped the stud, I would likely have this out by now.  But I had to start grabbing with vise grips and then re threaded which started reducing the total diameter of the stud.  I probably could have removed with the Stud Removal Socket early on.  All of the attempted turning and reduced thickness also made in my opinion a soft steel stud that much weaker resulting in the second break.  

So now, I have drilled a tap hole very close to center of the stud.  I have this final fantasy of tapping slightly smaller than the 8mm hole and removing what is left of the original stud in pieces.  My main concern is that I will damage the threads in the fork leg.  This would then force me to either use a thread insert or just replace the fork leg.  I really like my fork legs and have Race Tech springs and the fork oil set up really nice.  I suppose a swap to another fork leg and rebuilding both forks is in cards if this stud replacement goes completely bad.  I am really kicking myself for what I have done.  A momentary lapse in sound judgement followed by hasty choices to extract have resulted in countless $$$ and hours of frustration.  
Any suggestions are welcome.  However, if any of you suggest I weld my toolbox shut, remember, I do not have any welding equipment.  You will need to bring yours over and do it for me.    ...Please.  
KZ RIDER RELAY FLAG CARRIER #55
1977 KZ650B Ready & Fit to Roll Anywhere!
1974 F7 175 -first bike and still own, full resto soon!
2002 ZRX1200R -Red the faster color
2011 Concours 14 -Now a Snarling Wolf in Sheep's Clothing!

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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 29 Mar 2022 11:37 #864484

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Hi Forest, did I mention those sockets have a good grip   if your drill hole is close to centre then you can drill to 7mm then carefully with a pin punch collapse the remains of the broken stud towards the middle (take your time and be accurate) with the debris out you can then drill to 8mm and insert a helicoil (I would think a basic kit would be around $20) MAKE SURE THE DEBRIS IS OUT BEFORE DRILLING TO 8mm (the steel debris will kick the drill into the softer alloy) It's a bit of a faff but not a lot of cash to save the leg
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KZ 650 Front Fork Pinch Bolt Stud - Help Please! 29 Mar 2022 14:10 #864488

  • Mikaw
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I have used Wookie58’s technique before. It does work. There are shops that will electrically burn out the broken stud. I did a search and come up with “MDM” process but that doesn’t sound like what I have heard in the past. If you have it drilled out have you tried Left Handed bits?
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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