Bugger ... snapped suspension mounting bolt!

[gijoe1313]

Righto, Donor and I were working on his Suzuki Intruder VS700 installing new rear shock suspensions ...

All was going find until one of the bolts went and snapped itself! :pinch: What we need is someone who has the knowhow to go about fixing this predicament!

Donor: We were using a torque wrench, but had omitted to change the washer, so subsequentl over-torqued the nut. When trying to undo it to replace the washer, TWANG!

Many rude words were forthcoming - clean shearing of the stud from the bike frame, and it's looking like a long walk home in me bike gears at the moment.... back to the wordsmith whilst I go kick small children to cheer myself up...

So help please ... anyone not out riding who can help can PM or txt

027 6723 786 (Donor)

:argh:

[gijoe1313]

Right Donor and I working on his rear shock when one of the rear mounting bolts sheared off ... need help ... click here! http://www.kiwibiker.co.nz/forums/showthread.php?p=2001861#post2001861f

Thanking you kindly for your perusal and any assistance gratefully accepted! :sweatdrop

[smoky]

You got a drill and a file?
Pop down to Repco and buy an 'easy-out'

file the end of the sheared off bolt flat, centre punch it, drill with a small pilot, then drill it with a slightly larger drill bit.
Then wind the 'easy-out' bit into the hole - they are a tapered threaded thing that as you wind it in counter clockwise it grips and winds out the snapped off bolt.

Good luck

[Squiggles]

I think the bolt is part of the frame, and the nut is what they were doing up... makes things a bit harder :doh:

[gijoe1313]

Thanks for the reply smoky, but the bolt is actually a mounting stud from the frame! So needs to be ground off and another welded to replace, a job a bit beyond our backyard tree-shade mechanics! :pinch:

[JMemonic]

Looking at the photos changing the washer is not the cause of the problem, it not that you were over torquing it but that its been damaged previously, ok I could be wrong but on the third photo there appears to be a discolouration of the metal towards the top and on the left hand side a shine that seems off, needs someone on the scene to say for sure.

[munterk6]

Ahh...she's buggered mate. Simplist way out is to replace the bike....with a GSXR Suzuki lol! (bit of an expensive option tho' hehe) :doctor::doctor:

seriously? looks like ya need an engineer to sort it eh, ya dont want that shockie falling off whilst you're riding now do you.
Good luck Justin. :msn-wink:

[Ixion]

If Im interpreting those pics correctly, the stud welded to the frame has snapped level with the outside of the shock mount. IE the stud still goes all the way through the shock mounting hole? If so, a temporary get you home would be to drill and tap a small short hole into the centre of the stud and secure the shock with a small bolt screwed inot the stud. Almost all the load is axial along the axis of the shock (ie , up and down). The nut is just there to stop the shock wiggling its way off. I've actually ridden many miles , obliviously, with a shock nut completely missing. The sideways force is very small.

The long term fix is to take it to an engineering shop with a stud welder. Specialised gadget ., but very easy. I imaginbe a MIG could do a reasonable job also.

[CookMySock]

Or else just wire it on. How far do you have to go ?

Steve

[Maha]

Be sure to get a cake made!!!!!! :drool:
And bring the rest up here for my supper, go on, ya know ya want to...

[Motu]

a temporary get you home would be to drill and tap a small short hole into the centre of the stud and secure the shock with a small bolt screwed inot the stud. Almost all the load is axial along the axis of the shock (ie , up and down). The nut is just there to stop the shock wiggling its way off.

Do it.This is how the shocks are held on my TLR200,and it gets a lot more abuse than a street bike.I've bent the shock,but it has never come off.

The pit falls of relying on a torque wrench.Learn how to ''feeeeellll'' the correct torque.You should of felt it starting to give long before you sheared a 10mm stud.

[gijoe1313]

:lol: Actually this was removing the nut from the bolt! All good, Donor and I got the trailer reWOFed and Regoed and then off to Frosty's we went.

After the usual larrikin conversation (actually we never let up), it turned out it was all Frosty's fault! :msn-wink: Dismantled half the frikk'n bike only to find out what he already thought needed to be done ... one step forwards two steps back sorta thing.

Anyhow, Donor will be acquiring a die and tap set and will go about bollocking up the job even more! :whistle: Thanks for the replies guys, Donor is a bit bemused by the whole process, as for me - spannering on bikes is all good :yes:

Now, I should go back to my original plan from yesterday and continue work on the lekky bits on Betsy (Chancey's RZ350 which I have deigned to borrow permanently off her! :innocent:)

Very interested in that process Ixion mentioned ... cor lumme, these engineerink boffins are wot wot what? :scratch:

[FROSTY]

yup ZE nut had broke off good.
Just for the record -doing these jobs ALWAYS use metric fine thread bolts.

[Donor]

S'fucked good now.

Tap broke in the hole.

Don't give a shit really.

Time to get rid of it anyway.

[gijoe1313]

Well, I have just got home ... and about to work on my original job of fixing Betsy's lekky bits ... and this weekend, I have done just about every job that wasn't doing it! :no:

Poor Donor, after a madcap rush to Mitre10 to get a hammer drill, a good 5mm bit (and a heat gun for me), the resultant mishmash was ... not good :no:

One snapped off thread cutting tool in the most excellently drilled hole :(

Anyhows, I'm now back off to getting on with Betsy's lekky bits finally ... :baby:

If anyone has some good ideas, I am peachy keen to hear them and see how this whole sorry saga can be resolved in a favourable light! :calm:

[Bonez]

How thick is the peice the protrution mounts onto on the frame? You could cut the mounting mount off flush, drill it, tap it and put in a suitable sized stud or bolt. Then weld it in position if needed.

[DMNTD]

Yep...I definitely just buy a new bike :shifty:
I hope this has been of help :eek:

[Ixion]

Broken tap = Not Good.

Time to get it on a trailer to an engineers. Cut of original mount weld on new one.

Oh, and suggest send the gorilla to get the chips next time.

[Bonez]

The tap could also be able to be arc erroded out.

[xwhatsit]

Fuck a duck!

There's a law I'm sure Mr Ixion is familiar with, the Law of Conservation of Fettler's Luck. Luck is never lost or gained, it's merely transferred from one biker to another, or held temporarily in another medium to be restored further down the track.

My workshop day on Saturday went far too well; the headset bearings just about punched themselves out and the fork seals were a piece of piss. It went so easy I got quite worried towards the end. Sounds like I enjoyed a surplus of Fettler's Luck while you suffered a deficit.

[TOTO]

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[geoffm]

One way if there is a bit of stud poking out is force a nut onto the remains and zap it with a mig welderdown the centre. Th eheat hlps loosen the thread, and the nut means you can put a spanner on it.
BTQ, don't buy taps from Mitre10, as you may have noticed, they are crap. Blunt, poorly shaped, no relief and made of Chinese cheese. Buy some decent Sutton ones from an engineers supplies. And use lots of tapping lube and a proper tap wrench.
G

[gijoe1313]

Broken tap = Not Good.

Time to get it on a trailer to an engineers. Cut of original mount weld on new one.

Oh, and suggest send the gorilla to get the chips next time.

Ayup, coincidentally I have a student that actually can help out ... his dad owns an engineering firm in East Tamaki and the lad actually works in the place and reckons he could turn it out himself (milling machines, CNC the works ... )

Reckons also it would be a good project for him to do since it "helps out a cool treacher who rides bikes which is superkewls...".

Good gravy, a keen as mustard lad who is motivated to actually want to do something? I think I will look for a zip in the back of his head ... :shifty:

[FROSTY]

OR you could do as I suggested on saturgay and leave it with me to sort out. :2guns: