Question about replacing suspension bolt

[Sparkster]

I have a 1980 GS850G and recently removed the nuts on the suspension bolts to do some work. The left one was crossthreaded and has sheared off most of the threads. I've read about the various solutions but wanted to check the opinions of those in the know about something...

I'm thinking of cutting the remaining bolt off, drilling a hole, and replacing it with a carriage bolt utilizing the new hole.

1) Are those bolts welded to the frame for any major reason and would replacing the welded bolt with a carriage bolt render the bike unsafe?
2) If this sounds viable how do I compress the spring on the shock to easily remove the suspension without killing myself?

Right now I have simply drilled a hole in the ruined bolt and placed a cotter pin in there as I have read that there is no latteral pressure from the suspension and so I'm assuming that it will be safe enough to get me somewhere to fix it properly if the above isn't viable.

Thanks for your time!

[DanTheMan]

If you put the bike on the centerstand (and lock the center stand with a hardened steel pin), the shocks will extend to their max length. You can then remove the shock. No harm will be done if you put a shock mounting bolt in there. I don't remember if the stud is welded or not, but if it is, cut it off flush, center punch it, progressively drill it out, keeping the drill horizontal to the work until you have the right diameter for a shock mounting bolt (auto parts stores have them) and re-install the shock.

[Steve]

I would not use a carriage bolt. They would probably not stand up to the stress of the suspension. :shock:


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[chef1366]

I'd recut the threads with a die.

[waltfen]

I've just had the suspension bolt on my GS650 replaced. Some numpty had snapped the threads off by overtightening without having enough washers on.
I bought a scrap frame for £10 and a small local welding company removed the snapped one and replaced it with the one off the scrap frame.
Cost me £20 and I was well chuffed. The welding is probably better than factory.
The original bolt goes through the frame and is welded at both sides and so is my replacement.

[Sparkster]

If you put the bike on the centerstand (and lock the center stand with a hardened steel pin), the shocks will extend to their max length. You can then remove the shock. No harm will be done if you put a shock mounting bolt in there. I don't remember if the stud is welded or not, but if it is, cut it off flush, center punch it, progressively drill it out, keeping the drill horizontal to the work until you have the right diameter for a shock mounting bolt (auto parts stores have them) and re-install the shock.

Exactly what I needed to know, thank you. I only mentioned a carriage bolt b/c I thought that's what was in there; I had noticed that part of it had no threads. I'm a non mechanic so this is/has been a HUGE learning experience.


There will be no cutting of threads here, I'm afraid. The last 1/4 inch of the bolt is bent at a fierce angle (don't ask, it was like that when I got it). Time to just rid myself of it and replace it with a new one.