Broken Bolt in Fork - Questions, Ideas?
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Cruiser
Joined: Dec 2022
Posts: 111
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From: Jax, FL
Broken Bolt in Fork - Questions, Ideas?
On my 2003 Heritage Softail Classic there is a bolt that goes into the top-outside of each fork, into the upper bracket. It holds on the aux lights, the wind screen, and in my case the fangs. Today AI noticed the entire assembly was rattling around. Investigating, I found that the bolt itself is not loose, it's BROKEN! Of course, it's not sticking up, so there's nothing to grab. Note, it doesn't appear to be rusted, but it looks like there is locktite on the threads.
I'm looking for ideas to get the bolt out. I think I'm going to try some left-handed drill bits to see if I can just get it to spin out. Failing that, I'm going to drill a slightly larger hole and cut some new threads. Failing that I'm just going to buy a used upper bracket from Ebay. I'm no kind of machinist, so if anyone has tips for me or other ideas I'd love to hear them. I'm thinking liquid wrench while I wait for my drill bits, then some heat as I drill.
I'm looking for ideas to get the bolt out. I think I'm going to try some left-handed drill bits to see if I can just get it to spin out. Failing that, I'm going to drill a slightly larger hole and cut some new threads. Failing that I'm just going to buy a used upper bracket from Ebay. I'm no kind of machinist, so if anyone has tips for me or other ideas I'd love to hear them. I'm thinking liquid wrench while I wait for my drill bits, then some heat as I drill.
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,086
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From:
Using a parts finder might make it easier to better the identify broken bolt.
Here is a parts finder link
https://partsfinder.onlinemicrofiche...rleydavidsonmc
Here is a parts finder link
https://partsfinder.onlinemicrofiche...rleydavidsonmc
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,086
Likes: 1,128
From:
Is it the same bolt that holds windshield bracket mounting point?
Then perhaps removal of windshield, mounting parts, spacers, light bar and whatever else should eventually expose the broken bolt..
Then perhaps removal of windshield, mounting parts, spacers, light bar and whatever else should eventually expose the broken bolt..
Thread Starter
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Cruiser
Joined: Dec 2022
Posts: 111
Likes: 62
From: Jax, FL
Yeah, that's the one. I've already pulled all that stuff off. It's beneath flush. Thanks though.
Stellar HDF Member
Joined: Aug 2012
Posts: 2,664
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From: Indiana, USA
Drill a hole and use an easy out. Drilling should heat up any LocTite and easy out is similar to your LH drill but more common
https://www.craftsman.com/products/c...Z_OD4o-odAfDL_
https://www.craftsman.com/products/c...Z_OD4o-odAfDL_
Thread Starter
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Cruiser
Joined: Dec 2022
Posts: 111
Likes: 62
From: Jax, FL
Using a parts finder might make it easier to better the identify broken bolt.
Here is a parts finder link
https://partsfinder.onlinemicrofiche...rleydavidsonmc
Here is a parts finder link
https://partsfinder.onlinemicrofiche...rleydavidsonmc
Ronnie's Harley-Davidson | SUSPENSION - FRONT FORK ASSEMBLY W/ STEERING STEM
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From: Las Vegas
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Seasoned HDF Member
Joined: May 2008
Posts: 21,174
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From: South Carolina
Have you tried a punch to rotate the broken off bolt?
It may be loose now that it has no tension on it.
HD seems to be very secretive about the part number of this bolt.
I think it is a 5/16-24 x 1-1/2 Grade 5 Bolt,
It may be loose now that it has no tension on it.
HD seems to be very secretive about the part number of this bolt.
I think it is a 5/16-24 x 1-1/2 Grade 5 Bolt,
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Thread Starter
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Cruiser
Joined: Dec 2022
Posts: 111
Likes: 62
From: Jax, FL
Thanks for the info. I have the bolt from the other side. I'm just going to match it with something from the hardware store.