Fork clamp rounded bolt

[Barko99]

Forks need seal so I went to simply drop them and have someone  replace but the left top bolt is rounded and stuck. Tried special tools but that only made  it worse and where it is located it's hard to get at to get out. My choices seem to be take off everything,  ramaybe air headlights, etc. Which I loath. Or drop the tree but I'm afraid of losing bearings, or??  Which is going to be easier? Help, poor thing is stuck in my shop. If you want to fix you get buy it cheaper! Tjhanks

[tthompsr]

Had the same thing happen to me last year while doing a head bearing swap, It was easy once I pulled the triple tree, I was able to drill a hole in the bolt and use a extractor. I was lucky mine was the right lower bolt which allowed me to pull the fork assembly, not so easy with your situation. looks like your best bet is to take everything off to allow you to get to that bolt. A side angle drill might be handy. good luck!

[Gixerhp]

Weld a good nut onto the head of the damaged bolt, if you cant do any thing with vise grips and heat,, the flame wrench allways helps,,

[Gixerhp]

Also these work great too.. and a gain use some heat to loosen the thread locker

http://www.sears.com/craftsman-10-pc-damaged-bolt-nut-remover-set-low/p-00952166000P?sid=IDx01192011x000001&gclid=CjwKEAjwqZ7GBRC1srKSv9TV_iwSJADKTjaDkuPUm-XGvxqgy6WMWygpPWLyPccUzC9-YWHLIzk3GBoC4cXw_wcB&gclsrc=aw.ds

[Barko99]

I tried the sears type tool but it just rounded it off more. Bought a new 90 degree drill and I'll see if that'll work. Thanks

[VirginiaJim]

I've had good luck with Snap-on sockets but if it's too rounded they won't work.

IRWIN BOLT-GRIP Extractor Expansion Set, 5 Piece, 394002

[motonerd14]

I've had good luck with Snap-on sockets but if it's too rounded they won't work.

IRWIN BOLT-GRIP Extractor Expansion Set, 5 Piece, 394002

I just bought that same extractor kit a few weeks back and it works very well.