Forum menu
I want to replace the spring in my 2010 boxxer teams.
I took the bottom out adjustment cap off... and it looks like my mechanic has overtightened the 24mm top bolt for the bottom out adjustment cartridge (which holds the spring) ... because when i have come to undo it, it has rounded off the corners and wont get purchase! any suggestions? i have tried an adjustable spanner but that wont grab onto the bolt as it is only a couple of mm high... Please HELP!
Get hold of a correctly sized socket that bears on the flats - lots of them do. Using an adjustable spanner on a shallow soft alloy bolt is just asking for trouble - don't do it.
As above you need a 6 sided (not multi point) socket the right size to get it off.
cheers guys :-), but yeah i tried the 6sided 'hex' socket but there is a slight chamfer on the inside edge which is nearly the same height as the bolt cap that is being un-done
Get that machined off flat than?
I would grind the socket down past the chamfer. I'm guessing you'll struggle with a hacksaw, so maybe pop in an engineers and get them to grind a few mm off it.
already tried that... must be hardened steel as it went through my lathe bit and hardly left a mark on the socket!
You have used the wrong type of turning tool or spindle speed was far too fast.
Try suing an angle grinder or similar on the socket.
actually yeah the spindle speed may have been too fast... cheers... might try the angle grinder suggestion
[i]and it looks like my mechanic has overtightened the 24mm top bolt[/i]
[i]i tried the 6sided 'hex' socket but there is a slight chamfer on the inside edge which is nearly the same height as the bolt cap that is being un-done [/i]
but it's the mechanics fault the thing rounded off?
Had to so the same for the 6pt socket I used on my Floats.
I just clamped it in a vice and filed the face flat and that works just fine. Took a bit of time mind...
dont get me wrong... its totally my fault for rounding it off... but it certainly isnt done up to 7.5Nm like the service manual directs.
there is a slight chamfer on the inside edge
Yeah, thought that might be an issue (but optimistically disregarded it!).
If you can't grind it down get hold of a box spanner - I don't think I've ever seen one of those with a chamfer. They bear on the points but unless it's completely borked I'd hope you'd be OK.
[img] 
[/img]
nice idea on the box spanner! i'll see if i can get a 24mm one
Maybe it's obvious... But make sure you undo the bolt on the upper crown first, or you will never move the top cap!
Maybe it's obvious... But make sure you undo the bolt on the upper crown first, or you will never move the top cap!
Was about to say that too! If the threaded section on the top cap extends past where the upper crown clamps, the crown clamp can compress the leg and hold the top cap in.
That, plus a ground (not turned, it's hardened) socket should do the trick.
cheers. yup, un done the crown bolts and have a freshly ground socket... gonna try it out in the morning... thanks for your help guys 🙂