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AzMtnThumper

XR Fork bottom Bolt

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I am in the process of replacing both fork seals and two bushings on my 93 XR600R. Everything went just as outlined in the manual (Honda) until I tried to tighten the bottom bolt into the bottom piece. It won't tighten much beyond finger tight. The Honda shop manual (93') doesn't give a torque spec for the bottom bolt. The bottom piece seems to just rotate inside the piston tube and retainer as I try to tighten it. The only special tool listed in my Honda manual is a tool for the retainer. I looked at the cartridge holding tool at the Race Tech website and it doen't look like it could possibly work on my forks??? Am I missing something? How tight should this be? The printout I got from Race tech said 25 in/lbs (they listed it as Compression Valving Shaft Nut Torque). Any help or ideas would be appreciated.

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your best bet is to use an impact gun, 3/8 should do it. also, sometimes the cartridge will still spin when you use the impact. so clamp the upper tube in a soft jaw vice and pull down on the outer tube as you tighten. that should put enough pressure on the cartridge to hold it. the bottom bolt torque is 25ft.lbs

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Thanks YZFXR, I've tried a 1/2" impact very gently but when I turned the air way down to prevent damaging the aluminum threads it didn't spin very fast. I think I'll try a 3/8" butterfly impact (also down) and see how that goes. I was thinking that maybe a little bit of loctite that was well cured on the inner retainer surface might help to prevent the spinning.. Thanks again for your suggestion.

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that butterfly wrench should work good. when i put the fork in the vice and pulled against the rebound spring i was actually able to tighten the bolt down by hand with a ratchet and then used a torque wrench to finish it off.

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