Nasty Allen head - Fork oil drain bolt - Steve Saunders Goldwing Forums

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post #1 of 8 (permalink) Unread 04-19-2019, 01:45 PM Thread Starter
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Unhappy Nasty Allen head - Fork oil drain bolt

Past mechanics did a number on my fork oil drain bolts. Why do motorcycle manufacturers tend to use shallow hex-head bolts? There is room for a deeper bolt head. I have found this is true for both Jap and German made bikes. Compare these to a Dorman Allen head bolt and the head on the Dorman bolt is 50% deeper and they don't strip out like these!

I just received my new Pirelli MT66 tires and decided it would be time to pull the front forks, drain and clean the TRAC system too. The right side came right out and the other side is bad. I have the 6mm socket and allen key and neither will budge it; the Allen key just slips.

I have extractor tools. I'll try, but they often do not work. I'm ready to drill out the bolt. I hung the fork upside down over night and most of the oil leaked out of the top seep hole.

Should I start drilling, or any suggestions?

Thanks, JD
1984 Goldwing Standard
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post #2 of 8 (permalink) Unread 04-19-2019, 03:42 PM
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Honda installs a thread locking agent to those screws. The trick for trouble free removal is to keep fork under tension by not removing spring cap bolt, then heat the head of allen bolt and removal by way of air impact wrench. Works every time.
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post #3 of 8 (permalink) Unread 04-19-2019, 04:34 PM Thread Starter
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I can see where the heat helps to break the thread lock, but I’m past that point here. Past mechanics buggered the hex opening, likely using an impact and not inserting completely. This bolt will NOT be turned by an Allen key anymore. It slips immediately.

Thanks, JD
1984 Goldwing Standard
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post #4 of 8 (permalink) Unread 04-19-2019, 05:12 PM
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Try a torx bit a little larger and hammer it in, the hammering usually loosens the bolt.
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post #5 of 8 (permalink) Unread 04-19-2019, 05:14 PM
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Just a thought, , buggered Allen head screws can be a BIG problem, , ,I have had very decent results with using a latex glove over the allen wrench before inserting the tip onto the buggered hole. It might be worth a try, , ,


I haven't seen your problem bolt and I don't know if this will help, , ,but possibly a combination of "heat" and the glove trick might work.
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post #6 of 8 (permalink) Unread 04-19-2019, 07:30 PM Thread Starter
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Thanks all. Good news; I just got it out!

I used the heat idea from DriverRider and I was about to try Dave’s Torx idea.

Last night I had hammered in an easy-out bit. Once I pulled the cap and spring and emptied the oil, I got it set nicely in a vise. Heated it up via the bit, which likely seated the bit more and it came out. Usually these bits pop out, but this one stuck so hard it was hard to get the bolt off after. It is a Craftsman USA made tool. I’ve had the set for 40 years.

The Torx is a good idea. There will always be a next time. Now I just have to clean and rebuild the forks, pull and mount tires! Thanks again
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Thanks, JD
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post #7 of 8 (permalink) Unread 04-19-2019, 08:14 PM Thread Starter
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Got the rubber off the front. Whew! It’s quitting time and I need a drink!
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Thanks, JD
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post #8 of 8 (permalink) Unread 04-20-2019, 08:30 PM Thread Starter
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Moved to new thread...

Thanks, JD
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Last edited by JohnnyD; 04-21-2019 at 12:05 PM.
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