Arrrghhhh - fender bolts! (long vent)

[stephan]

So I decided that this past nice and stormy weekend would be a great time to do the whole front fork oil seal, 15wt oil, progressive spring swap.  I don't think I've ever ran into so many problems working on a vehicle in my life!

Problem #1:  Axle bolt stuck on REAL good!  So after wrestling with that for a while I finally got a wrench on one side, a socket on the other and a hammer to convice the sucker to let loose.  Which, happily it finally did - whew!

Problem #2:  Brake caliper bolts welded on!?!?  Okay, not really but almost!  The book shows hex head bolts, but mine are large Allen head bolts - go figure.  Finally after I used an Allen wrench with a 15/16 wrench as a breaker bar it let loose with a metallic squeal.  Luckily they didn't break off - whew again!  Oh, BTW time for new front shoes too.

Problem #3:  Ahhhh, yes the wonderful fender bolts.  Two out of four isn't bad . . . except when you need to take all four out!  Two came our great, the other two Allen bolts I rounded off quite nicely, thank you very much!  Well one I was able to get out by holding the bolt with pliers and using a socket on the nut on the underside of the fender.

Now as for the last fender bolt . . . . well it was an adventure.  I tried to dremel out a slot and use a slotted screwdriver but it kept twisting.  I finally ended up breaking the head off the bolt and it let loose - yeehaw.

Problem #4:  I HAD a small fairing on the front of my bike, but as I took it off to get to the fork top bolts it kind of fell apart.  There were some small cracks in it that broke apart when I took the bolts out.  Not a big deal, but still a pain.

Problem #5:  You got it, the damper rod bolt.  Spinny, spinny, spinny!  Well, I've got that one figured out thanks to past experience on this board.  A trip to Lowe's or Home Depot, a couple of massive bolts and a coupler should do the trick here.  Oh BTW, the broom handle idea doesn't always work!  

All in all, it was an interesting weekend.  So far I've got about 5 hours invested and my results are a GS500 that looks like it was in an accident.  Oh well, it will all come together in the end.  I have enjoyed the experience I've gained, and the fact that I'm not paying to have it done!

Thanks for the opportunity to vent a bit!

Ride safe!  

[MarkusN]

Replace those fender bolts with Torx type if you can get them. Allen drive on countersunk screws is a PITA, especially if there is corrosion hazard.

[Kerry]

I have enjoyed the experience I've gained, and the fact that I'm not paying to have it done!

Yeah, just think if you'd taken it to the shop!

Mechanics aren't necessarily as careful with your bike as YOU would be, and all of those stuck bolts could have cost you a fortune in labor!  (Unless you held them to some kind of published time-per-procedure.)

[Alias]

Fork seals suck. Last year I paid $60 + parts for my Katana. The GS is going to the same guy this year :p. I do everyhting else, I just don't wanna mess with them. Its worth the $60.

[Turkina]

Wrap some teflon tape around the Allen wrench before using it.  Insert it into the screw, and tap it in (make sure it's lined up!)  It'll give a tighter fit and keep the screw from stripping out.  That's how I dealt with the fender screws!

[Jeff P]

Good topic.  Two of my fender bolts came right off, one I had to slot with a dremel so I could use a screwdriver, the other I had to completely chop apart.  I got some regular hex head bolts to replace 'em.  Luckily I didn't have the rest of those problems!  :mrgreen:

jeff

[stephan]

Thanks for the great ideas and support!  

I got some hex head bolts to replace the old destroyed fender bolts.  I've created the tool to get the damper bolt to let loose, and I've epoxied my fairing and strengthened it a bit.  Hopefully all goes well tonight.

As much as I complain, I enjoy working on my GS - am I sick or something!?  

Stay safe!