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Lower fork bolt rounded. Thoughts on removal?

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  • Lower fork bolt rounded. Thoughts on removal?

    The bolt on the very bottom of my left-side fork was rounded when I went to pull it apart and replace the fork seal. I can't cut a slot for a screwdriver with it in there like that, I don't have a Torx bit that fits in a 6mm Allen hole, and my EZ-Out won't reach far enough. I don't have any ideas on how to get it out from here. Does anyone else?

    EDIT: Alternately, is there any way to replace the old fork seals without tearing the fork apart?
    Last edited by thebook92; 04-19-2015, 03:21 PM.
    1995 600 w/ 750 swap (aka the cause of 90% of my current headaches)

  • #2
    Carefully drill the head off or as some say works drive the next size Allen wrench into it.
    "I'm sorry, I didn't mean to upset you when I called you stupid. I thought you already knew..."
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    • #3
      I've drilled the head off before. Not super easy but definitely doable.
      1998 Katana 750
      1992 Katana 1100
      2006 Ninja 250

      2006 Katana 600 RIP - 130k miles

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      • #4
        I did try the bigger Allen method but nothing I have fit. Looks like I'll be drilling it out. What size drill bit should I use? I'm thinking a 3/8" one should do the trick.
        1995 600 w/ 750 swap (aka the cause of 90% of my current headaches)

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        • #5
          Originally posted by thebook92 View Post
          I did try the bigger Allen method but nothing I have fit. Looks like I'll be drilling it out. What size drill bit should I use? I'm thinking a 3/8" one should do the trick.
          Use a 5/16" drill bit as that is the same size as the bolt itself, All you want is to just drill the head off the bolt and no further.

          Tmod

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