Dual tone horns & fork gaiters

[wal750]

Are these the gaiters ?  http://www.ebay.co.uk/itm/TRIUMPH-BSA-N ... 43a6639541

Yep, the very ones - perfect fit.

Just for info these are Hi Level part number 263681

[Brockett]

Inspired by "Cabra" and bored in the winter I decided to fit some fork gaiters.
Then the problem. The large pan head allen bolts that hold the mudguard have siezed.
The first time I tried it the tool kit allen key broke and a shard of the key hit my glasses ( could have had my eye out). Undaunted I gave it a spray of WD and left it for an hour before applying a "quality" allen key. Just as I thought it had cracked it I realised the inside of the allen keyway had rounded off. Hell that's tight. Now I am faced with drilling it out and hoping to not ruin the mudgard.
Has anyone got a better suggestion?

[cabra]

The large pan head allen bolts that hold the mudguard have siezed.
The first time I tried it the tool kit allen key broke and a shard of the key hit my glasses ( could have had my eye out). Undaunted I gave it a spray of WD and left it for an hour before applying a "quality" allen key. Just as I thought it had cracked it I realised the inside of the allen keyway had rounded off. Hell that's tight. Now I am faced with drilling it out and hoping to not ruin the mudgard.
Has anyone got a better suggestion?

Yep - good old Suzuki   If you recall my post, I did suggest leaving the guard on - for that very reason! I'm afraid there is no alternative but to get the drill out. Do not bother trying to save the threads in the fork leg - it won't happen - just drill as close to centre as you can, no need to be toooo fussy, near enough will do. Sounds scary,   it's the thinking about it bit that's scary, just make sure your drill bit is sharp/new & you drill straight - Oh    might be an idea to remove the front wheel - you don't want to have to buy a new tyre as well!!!! Replace screws with stainless (dome head - whatever) bolts and nylock nuts. Job done
This seems to be a "standard" problem, the screws seem to "weld" themselves into the fork sliders, copperslip is the only answer - try telling that to Suzuki though   ! - Have fun  

[Brockett]

Cabra, thanks for the advice and support with this.
I am trying to work in a very small dark shed and there is just not enough elbow room to get the forklegs out as pair complete with mudguard. So out they come one at a time. Following your post and some deep breaths I used a hacksaw to cut a slot in the bolt head and then shallow drilled it. I used a hammer and drift to turn the heads off the bolts and removed the mudguard. With this done I took off one leg at a time and put them in a black and decker 'workmate' and carefully drilled through with a 3.5 mm drill ( in the warm and well lit kitchen). I finished off with a 5mm drill and then ran a 6mm tap through it. I have a couple of "propper" allen bolts which will make a fair temporary fix untill I can get hold of some stainless bolts and washers.
On a brighter note the gaiters are a really good fit and look great.
I shall have to give serious thought about the horn upgrade.

[cabra]

Well done Brockett48, that is the other way to do it    Like I said, it's the thinking about it before hand that gives you the willies.  

[Sven]

that gives you the willies.

Ain't heard that one for a few years  

[cabra]

that gives you the willies.

Ain't heard that one for a few years  

The old ones are ALWAYS the best      

[shameless_frank]

When tying back the brake calipers, is it just so they are out the way or to keep the pads held in? I've not got a centre stand, is there another way to hold the front up?

[Locky]

Its just to take some weight off the brake lines and to keep the calipers out the way , don't operate the brake lever when the calipers are off the discs . It could be hard to do without a centre stand .

[greywolf]

I hang my bike from the joists in the garage ceiling with ratcheting tie downs, remove the calipers, remove the front wheel and slide the forks out with mudguard in place as a unit.

[cabra]

When tying back the brake calipers, is it just so they are out the way or to keep the pads held in? I've not got a centre stand, is there another way to hold the front up?

As locksmith says, tie back to keep out of the way. No stand, humm - you will need the help of a mate to steady the bike while you jack up from the sump (having first removed the "sump guard") The best way, ideally, would be to suspend from a joist in you garage, or what ever, using a strap around the handlebars between the clamps. - Not ideal BUT be VERY careful if you use blocks of wood underneath the foot rest hinges to prop it up, especially if your "mate" gets bored and decides to clear off!!  Also, be careful with the mudguard bolts, if that is the way you want to go (see my previous post) Have fun, you CAN do it.  

[cabra]

Ha!! Pipped at the post by GW! Doh!!!! :violence-uzi: