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- Help! New to me 1400 Intruder. Jacked the threads on upper fork tube.
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08-23-2020 #1Junior Member
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Help! New to me 1400 Intruder. Jacked the threads on upper fork tube.
Hey guys. Hoping for some advice here as I'm just hitting a wall thinking of a fix. So, I recently got back into the motorcycle world after a 15 year break and bought a 96 intruder that was needing to be saved from it's neglectful PO. Not overly pretty with all the pitting on the chrome, sagging signal lights, etc, but I was able to see some serious potential in this old girl. I have some grand plans including stretching the backbone and more but for now I'd really like to just enjoy getting to know her before the Pacific Northwest rain season makes its return appearance. After a few rides it became clear that the fork oil situation needed addressed because the front end dive was far too excessive. I set about doing a fluid change and seal replacement, and all was going smooth until I went to reassemble the top end of the left fork tube. It seems that when putting that goofy plug/bolt/spring retainer dude in I cross threaded it. By the time I realised it it was too late. I ended up buying a bent fork from a bonyard to aquire another of the bolt/plug whatever it is since the only other option I found was to wait forever and pay through the nose for shipping from Japan. Well, I went about reassembly round two today. The new plug bolt won't thread into the tube. Upon closer inspection, the threads in the tube are slightly buggered. I tried searching out a tap but apparently no one makes a 37x1.5, even the tap and die sizing charts don't list such a thing. I got creative and used the extra cap I now have and cut in 4 slices on the threads to make a sort of shade tree thread chaser, and although it did seem to do a little judging by the shavings after I ran it in and out a few times, that dam plug bolt still doesn't seem to want to run in. I'm trying to be careful not to damage this one since getting another has proved to be a pain in the arse. Anybody have any suggestions on what to do here?
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08-23-2020 #2
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08-23-2020 #3
If it was me I would slather up the slotted cap with coarse valve lapping compound and rum it in and out quite a few times. Clean really good and see if the new one starts to thread in. If it does start in slather it in coarse lapping compound and work it in and out Make sure you clean the threads really good.
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08-23-2020 #4Senior Member
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08-24-2020 #5Junior Member
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You've surely got a point. I just re-read myself and rambling to say the least. I'll try and clean up my post and get pics tomorrow morning before I head off to work.
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08-24-2020 #6Junior Member
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If it was me I would slather up the slotted cap with coarse valve lapping compound and rum it in and out quite a few times. Clean really good and see if the new one starts to thread in. If it does start in slather it in coarse lapping compound and work it in and out Make sure you clean the threads really good.
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08-24-2020 #7Junior Member
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08-24-2020 #8Senior Member
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I was a bit quick on that one...the pic shows just the external thread file;
The files without the nipple are for external thread repair only. The cut nipple added on the end allows the one tool to repair both the internal and external thread.
http://www.warrensvillefile.com/inde...ring-file.html
another option is this style:
Internal Thread Restorers
Model TF-50M: includes the toolholder and 3 sets of cutting blades for restoring internal metric thread pitches of 1.25, 1.5, and 1.75.
https://www.victornet.com/subdepartm...pair/1420.html
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08-24-2020 #9Senior Member
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I just looked at the parts image for your bike; I see what you mean when you say "goofy plug/bolt/spring retainer dude"...the spring stopper below the cap nut...is it steel or aluminum?
BOLT, FORK INNER
https://www.partzilla.com/catalog/su...glp/front-forkLast edited by TriNortchopz; 08-24-2020 at 7:24 AM. Reason: image has diff ref #
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08-29-2020 #10Junior Member
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[QUOTE=TriNortchopz;851652]I just looked at the parts image for your bike; I see what you mean when you say "goofy plug/bolt/spring retainer dude"...the spring stopper below the cap nut...is it steel or aluminum?
Aluminum. I'm guessing that was to prevent stripping the forks in the tube itself as that is steel.
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08-29-2020 #11Junior Member
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If it was me I would slather up the slotted cap with coarse valve lapping compound and rum it in and out quite a few times. Clean really good and see if the new one starts to thread in. If it does start in slather it in coarse lapping compound and work it in and out Make sure you clean the threads really good.
Thanks again
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08-29-2020 #12Junior Member
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I was a bit quick on that one...the pic shows just the external thread file;
The files without the nipple are for external thread repair only. The cut nipple added on the end allows the one tool to repair both the internal and external thread.
http://www.warrensvillefile.com/inde...ring-file.html
another option is this style:
Internal Thread Restorers
Model TF-50M: includes the toolholder and 3 sets of cutting blades for restoring internal metric thread pitches of 1.25, 1.5, and 1.75.
https://www.victornet.com/subdepartm...pair/1420.html
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08-30-2020 #13
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