Doing my chrome fork lower and Progressive monotube install. Tear down now complete. I got the 6mm bolt out of the bottom of the left fork, no problem. On the right side, unfortunately, the 6mm head stripped out. I can't get any traction on it at all. Any suggestions? My current plan is to take the right lower to the Harley place and get them to get the stripped bolt out. Surely somebody has a better idea...

 

I ran into this issue and stripped that hex bolt twice. I was able to use an impact gun to get them out.

 

How did you do it? I was using an impact when it stripped. I saw a YouTube video that used a slightly larger torx socket driven into stripped fitting. I thought about that, but decided I'd better get some advice first.

 

I would try that. That was the first thought that came to mind for me. Also, put some heat on it, and some pb blaster before hand. Be sure to get the torx beat in as far as possible, and square to the bolt.

 

Is leg out of bike?
Once stripped you really need the most force pushing against it to get it out.
For a stripped allen/hex:
A torx hammered tight into an allen/hex sometimes works
Sometimes a little JB weld on the allen/hex tool and placement in the head of bolt overnight gets you enough bite.
Sometimes a little heat is your friend.
The last line of defense would be to make a collar out of some electrical pipe or similar..maybe put a collar on a drill bit and drill the head off the bolt. Then with slider off you can remove the bolt with pliers. The collar is so you do not slip and hit the sides of the leg.
I had to drill one out and it was a major pain.

 

Yeah, the leg is out. I suppose could put the spring back in and then turn it upside down to put some resistance on the bolt. I have a heat gun and PB blaster, so I'll do both. I hope I don't have to go the drill out route. Wonder why Harley uses brass there in the first place?

 

I'm replacing these lowers with chrome, so I can pound on these a little harder than normal, if needed.

 

I don't know if this will help or not but Delboy has a YouTube video on how to remove a stripped Allen head bolt, here is the link . If it doesn't help sorry for butting in, if it does, great. Good luck.

 

Thanks for that. I don't think that will work here, as the head is not elevated. If I drill it off, there'd be no shaft to grab.

 

With my bolt it was stripped at the top of the head. I was able to hammer in an extended torx tip in there and use an impact gun.