What Size Allen Bolts Hold the Top Triple On?

[NiceGuysFinishLast]

Ok, I got my forks out, the new ones are ready to go in. However, I want to swap my '02 triple for my '89 triple first, then put the forks in, then put the controls back on. Well, I don't have an allen wrench big enough to remove the two allen heads that hold the triple on. They're part number 7 in this diagram.

Anyone tell me what size that is, so I can run out tomorrow and buy one? Thanks..

Jughead, the part number is: 1816741-001

If you can tell the head size from that, I'll be impressed.

Also, while I have you guys' attention, how do I swap the dust guards from my old forks to my new forks? Do they just slide off? They seem rather reluctant to move.

TYIA

[dgyver]

6mm

The dust covers are a little tough to remove. They are just pushed in. I have used a small screw driver to pry them up. Make sure you pry lightly as you move around the diameter.

[NiceGuysFinishLast]

Dgyver, you're a GS God. I guess I wasn't clear enough though. I need the size of the allen key to remove them, not their diameter. I have a 1/4" allen key that spins freely.

[Alphamazing]

Dgyver, you're a GS God. I guess I wasn't clear enough though. I need the size of the allen key to remove them, not their diameter. I have a 1/4" allen key that spins freely.

...?

6mm

[poolshark]

Dgyver, you're a GS God. I guess I wasn't clear enough though. I need the size of the allen key to remove them, not their diameter. I have a 1/4" allen key that spins freely.

...?

6mm

Yep. Did it three days ago. 6mm allen/hex key.

[Jughead]

Yeap 6mm.

[NiceGuysFinishLast]

WTF... 6mm < .25 inches

6 mm ~ .236220472 inches

.23 < .25

Therefore, my .25" allen wrench should not spin freely inside the head, it should not even fit. So... a big WTF?

[sledge]

A standard ISO M6 socket-cap bolt head (you call them Allen bolts which is not really the correct term) takes a 5mmAF hex key. An M8 takes a 6mmAF and M10 is 8mmAF. However the bolts may have an M6 metric-fine thread in which case the key size will be 5.5mmAF. Personaly I have got clip-ons so I havent a clue on the size but if the bolts are M10, a 0.250" key will spin freely which ties in with what you say. Confused?? carpet bomb the issue and go buy a 5.5, 6.0, 8.0 and 10AF hex-key...one of them will fit 

[GeeP]

Confused?? carpet bomb the issue and go buy a 5.5, 6.0, 8.0 and 10AF hex-key...one of them will fit 

Buy a whole damn set, you'll need them for something.  Don't buy the type with the "all angle" ball on the ends.  When you break off that little ball of mystery tool steel in the head of a deeply recessed screw you'll know why.   

[sledge]

Hey....good call

[poolshark]

Confused?? carpet bomb the issue and go buy a 5.5, 6.0, 8.0 and 10AF hex-key...one of them will fit 

Buy a whole damn set, you'll need them for something.  Don't buy the type with the "all angle" ball on the ends.  When you break off that little ball of mystery tool steel in the head of a deeply recessed screw you'll know why.   

If you've already got a 1/4" ratchet-set, head to wal-mart and pick up an entire (-ish) metric set for $10. Or pick up a set of regular L-shape allen-wrenches for like $5. For a once-every-now-and-then mechanic, they'll be all you need.

[NiceGuysFinishLast]

Yeah, I'm going to HD tomorrow to pick em up. I NEED to have the bike running so I can get to job interviews. I've got the forks/bars, and will soon have a wheel/chain. Awesome. For now, I'll ride on the old, rusted to crap chain.

[dgyver]

A standard ISO M6 socket-cap bolt head (you call them Allen bolts which is not really the correct term) takes a 5mmAF hex key. An M8 takes a 6mmAF and M10 is 8mmAF. However the bolts may have an M6 metric-fine thread in which case the key size will be 5.5mmAF. Personaly I have got clip-ons so I havent a clue on the size but if the bolts are M10, a 0.250" key will spin freely which ties in with what you say. Confused?? carpet bomb the issue and go buy a 5.5, 6.0, 8.0 and 10AF hex-key...one of them will fit 

These are not standard SHCS, I think they are at least 10mm dia (maybe 12mm) but use a 6mm Allen. I did not measure the body diameter since NGFL only wanted the wrench size.

[sledge]

DG?
Sounds like the bolts are specials, I am not surprised. The Japanese, unlike most of the rest of the world have their own standards and just love to make their own rules up when it comes to fastenings.....maybe its all that raw fish they scoff 

[The Buddha]

Those bolts are fat fat fat body, slightly slightly larger and super super thin head and tiny threads. Completely weird crap.
Cool.
Srinath.

[NiceGuysFinishLast]

So I went and bought a set of allen keys today. It's an 8mm bolt, not a 6mm. 8mm ~ .31496063 inches.

.314 > .25

So I was right. And you're all on crack. Or something.

[dgyver]

The ones I checked are 6mm. Looks like there are different bolts.

[NiceGuysFinishLast]

Weird. They fit my '89 triple too, although they stick up a good bit, since the triple isn't as thick there as the old one was. I think I'm gonna replace em, as they were stuck really bad and my allen key chewed em up a good bit... enough to cause sharp points to form and cut the crap out of my pinky finger.

Out of curiosity, what year did you measure? Seems odd that they'd arbitrarily switch a bolt like that..

[dgyver]

Not sure of the exact year, probably 94. I have several sets of them but from what I recall they all are the same. Most of my parts are from the early 90's. Fot the size of the bolt, it would make sense if the were 8mm.