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

 

They do not need to be put on nearly that tight as I am sure you have figured out by now. I do not remember the torque value, but I id mine by hand as per spec and no leaking.

 

- the bolt goes into aluminium.

- aluminium.

.

 

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!

 

I would try some thread paste first. You can pick it up at any hardware store.

 

thanks Texas. Dumb question: Do you mean the stuff plumbers use, permatex threadlocker or something else?

 

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 ;-)

 

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.

 

Thanks!

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.

 

I hope this helps service manual for an 09 Ultra Classic CVO says 72 to 96 inch pounds I don't know how old your request was but here's your answer