Fork Drain Plugs
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Tourer
Joined: Sep 2008
Posts: 440
Likes: 1
From: NW Burbs of Chicago
Fork Drain Plugs
Blew a fork seal last week. I couldn't find the torque spec for the drain plugs in the manual. Tightened them and then hit 'em with an impact driver (I was advised this was a good idea). Next day some oil around the plug. Plug spins freely. Oops. Got a helicoil at Autozone. Drilled it out using the specified drill on the package 21/64's. Tap spins freely. Look at tap which says 17/64's. Oops. Good news is 21/64's is the drill out for a 5/16's so now I have a hex bolt instead of the stupid metric (8mmx1.25 in case anyone needs to know - that was hard to find out on-line) phillips heads at least on one side.
But now I'm back where I was before. I can't find the torgue spec on the drain plugs in the manual
But now I'm back where I was before. I can't find the torgue spec on the drain plugs in the manual
Stellar HDF Member
Joined: Jan 2007
Posts: 3,447
Likes: 163
From: Northern VA
Stripped Drain Plug
Found this thread during my search and wanted to ask my question here.
The drain plug on my right fork is leaking so I replaced the old screw with a new one with the copper crush washer on it. That failed to stop the leak and it appears all the fluid has leaked out of the fork.
I'm trying to figure out what is the best way to fix this? Replace helicoil, retap with a larger screw, or replace the entire fork?
Can the repair be done with the fork still mounted on the bike or is a complete tear down of the front end in order?
(I installed the Progressive Monotubes last year, so the internal piece-parts should still be good...)
Thanks!
The drain plug on my right fork is leaking so I replaced the old screw with a new one with the copper crush washer on it. That failed to stop the leak and it appears all the fluid has leaked out of the fork.
I'm trying to figure out what is the best way to fix this? Replace helicoil, retap with a larger screw, or replace the entire fork?
Can the repair be done with the fork still mounted on the bike or is a complete tear down of the front end in order?
(I installed the Progressive Monotubes last year, so the internal piece-parts should still be good...)
Thanks!
Last edited by Plow64; Apr 23, 2012 at 06:39 AM.
Stellar HDF Member
Joined: Jan 2007
Posts: 3,447
Likes: 163
From: Northern VA
thanks Texas. Dumb question: Do you mean the stuff plumbers use, permatex threadlocker or something else?
Seasoned HDF Member
Joined: Dec 2010
Posts: 7,736
Likes: 1,524
From: Coromandel Peninsula New Zealand
You don't ever torque tiny bolts like that, you certainly don't use an impact on them.
A lot of H-D torque specs, particularly the ones in inch-pounds can be ignored as these won't be stretch bolts or have high-heat applications.
Ya gotta use some common sense and learn how to tighten things up without needing a torque spec for every nut and bolt....especially the smaller ones.
Most wrenches learnt this sort of thing as apprentices (and by making the mistakes)...I know I did ;-)
A lot of H-D torque specs, particularly the ones in inch-pounds can be ignored as these won't be stretch bolts or have high-heat applications.
Ya gotta use some common sense and learn how to tighten things up without needing a torque spec for every nut and bolt....especially the smaller ones.
Most wrenches learnt this sort of thing as apprentices (and by making the mistakes)...I know I did ;-)
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Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
On the tube I have it says "Teflon paste thread sealant" I use it on my primary and transmission drain plugs. With out it they leak.
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Stellar HDF Member
Joined: Jan 2007
Posts: 3,447
Likes: 163
From: Northern VA
Feedback: I tried the teflon paste, but the threads were stripped too badly for it to stop the leak. The cost of replacing the chrome fork leg was $189, quoted from the Dealer. Figured I'd try JB Weld as a last ditch fix before shelling out the big bucks. It worked like a charm. Only drawback is I have to disassemble the front fork if I want to change the fork oil in the future. I'll worry about that in 20K miles.
Last edited by Plow64; May 4, 2012 at 06:00 AM. Reason: Resolution to the problem
Stage IV
Joined: Mar 2023
Posts: 4
Likes: 0
From: Spring City, TN
I don't know if this will help you but the service manual on an 09 Ultra CVO says 72 to 96 inch pounds I hope that helps
Blew a fork seal last week. I couldn't find the torque spec for the drain plugs in the manual. Tightened them and then hit 'em with an impact driver (I was advised this was a good idea). Next day some oil around the plug. Plug spins freely. Oops. Got a helicoil at Autozone. Drilled it out using the specified drill on the package 21/64's. Tap spins freely. Look at tap which says 17/64's. Oops. Good news is 21/64's is the drill out for a 5/16's so now I have a hex bolt instead of the stupid metric (8mmx1.25 in case anyone needs to know - that was hard to find out on-line) phillips heads at least on one side.
But now I'm back where I was before. I can't find the torgue spec on the drain plugs in the manual
But now I'm back where I was before. I can't find the torgue spec on the drain plugs in the manual