02 1800 Front Right fork lower bolt - damper issues

[wieman1304]

Ok, so I have this 2002 GL1800 and I'm replacing the fork seals due to a leaking seal on the left side. The left side came apart without any issues whatsoever... Now on to the right side. Fork off the bike and in a vise. 6mm Allen.. the bolt "broke loose" great... Or so I thought.. I turn and turn and could not get it to back out. After a lot of cursing, thinking and finally using force to pull on the slider tube, I used an impact and the bolt came out. Here's my problem.. when I take a look at to why the bolt wouldn't come out, I looked and saw there were about 4 Cooper colored threads in the bottom of the damper. I tried reinstalling the bolt into the bottom of the damper and it stops at one point and the threaded portion of the damper spins inside the bottom of the damper.. I think I'm screwed and will need a new damper as I would never be able to tighten the bolt to specs after reassembly and it would leak. Am I wrong? Has anyone else had this happen?

[keithg64]

Threads in the bottom of the dampener ? As in the end on the bolt threads are stripped out ?

You may be able to re-tap the threading trend dampener and buyable new bolt.

[wieman1304]

No, they don't appear to be stripped. The end of the damper the part that it threaded internally, rotates as I turn the Allen head bolt. It rotates in the shaft of the damper.

[keithg64]

So its like the 2 peices have come apart from their tack weld or something like that ?

[keithg64]

Looking at other pictures you may be ok. It just may be the way its designed and may require an impact to spin the bolt fast enough to grab and lock in. I have a spare and will look.

[wieman1304]

Yes, it's like it broke loose on the inside at the bottom. The threads are a copper color at the point where there bolt gets stuck. Might have been that way from the factory, idk.. I think I'm just going to order a new one and see how it comes. If it's the same way, then I just return the new one. But I don't see having to use an impact to install it as none of the videos I've seen show or mention it. Maybe to remove, but not install. Thanks everyone for your help.

[keithg64]

I had a spare right fork cartridge that I looked at and mine spins too when I put a bolt in it and seat it to the bottom of the threads. It looks like it is in the tube by an O ring and a clip and that is how it should work. I believe the copper color at the bottom section of the threads is a Honda loctite. Just my theory and I'm sticking to it.

[GoldWingrGreg]

Yes, it's like it broke loose on the inside at the bottom. The threads are a copper color at the point where there bolt gets stuck. Might have been that way from the factory, idk.. I think I'm just going to order a new one and see how it comes. If it's the same way, then I just return the new one. But I don't see having to use an impact to install it as none of the videos I've seen show or mention it. Maybe to remove, but not install. Thanks everyone for your help.

I'm in the middle of a couple of fork OHs right now and went and looked at the threads in the bottom of a damper. The threads do look copper colorish. First off you should know that Honda uses lock-tights when those drain bolts are installed. Most who OH 5th gen GL1800 forks do not lock-tight when they reassemble. So, be sure all the lock-tight is removed from the threads.

Sometimes when I reassemble, I too am not able to torque the drain bolt after the damper is installed. What I do then is install the spring, washer, spacer, cap which then puts tension on the damper, and that will change the internal forces enough where I can then torque the drain bolt to 15-ft/lbs.

[keithg64]

So he should be able to put the fork back together and tension with the spring assembly if needed and he should be good to go.

[wieman1304]

After reading the replies, my bolt does not run all the way to the bottom. It stops less than half way in and the thread part starts spinning. (This is with the cartridge out of the tube). Even with the fork fully assembled, I was not able to tighten the bolt back up. I've ordered a new cartridge and bolt, so we'll see how this goes. I'll update when the parts come in.

[MikeB]

You do know that the lower bolt on the left fork is a different length than the bolt on the right fork right? Just asking.

Left Fork Lower Bolt - 90116-KV3-701

Right Fork Lower Bolt - 90116-383-721

[wieman1304]

Yes I do.
Thank You.

[wieman1304]

Well, I got all my parts and I ordered a new damper for the right fork. The new damper has what looks like a pin through the side of the bottom of it to hold the threaded portion in place. My old one didn't have that pin. Maybe someone had this same issue and they decided to make a change... who knows.. anyhow, I got everything together and back on the bike and she runs smooth as a kitten now. Only took her on a short ride so far, but it's much smoother than before. We'll see how she reacts to freeway roads soon.