Gen 4: 2011-2015 Front axle clamp (pinch) bolts safety wire - Kawasaki ZX-10R.net
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post #1 of 11 Old 04-27-2013, 04:51 PM Thread Starter
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Front axle clamp (pinch) bolts safety wire

Need advice on how to safety wire the front axle clamp bolts (A). I drilled holes, but the bolts are recessed way into the forks and once torqued, it's difficult to find space to run the safety wire through. Ideas?
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post #2 of 11 Old 04-28-2013, 01:30 PM Thread Starter
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No response? Does anyone make pre-drilled clamp bolts for this bike?
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post #3 of 11 Old 04-30-2013, 02:52 AM
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My only thought... Drill the holes about where the 'A' symbols are. There may be enough to get wire through for a locking. Yes, the locking won't be correct in the true sense, but it will stop the bolt from rotating around...

PS: What size lockwire you using? 0.025" or 0.032"?

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post #4 of 11 Old 04-30-2013, 05:43 AM
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Perhaps consider longer bolts, and drill the holes at the other end where they'd come out of the fork legs.

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post #5 of 11 Old 04-30-2013, 08:10 AM Thread Starter
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Quote:
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Perhaps consider longer bolts, and drill the holes at the other end where they'd come out of the fork legs.

Cheers,
Brian
So this is an interesting thought and one I've been considering. Need to look up some info or pics on how best to safety wire at the other end. Another thought I had was to replace the bolts with hex/flange heads...those that don't go through.

Thanks to all for input. Much appreciated.

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post #6 of 11 Old 05-01-2013, 06:47 AM
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Cheers mate, best of luck :)


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post #7 of 11 Old 05-01-2013, 10:28 AM
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It can be done using the stock bolts. Tighten them up. Mark the bottoms, as there is more clearance from the fork body. Drill them out & wola :-)

Like Nutter said above.

Axle bolt. Hmmm. Mine is not done but it passes inspection.

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post #8 of 11 Old 05-01-2013, 10:49 AM
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For the axle bolt, you can drill through at an angle, like this picture below. This is what I did to mine. Picture is from internet though:



For the pinch bolts, I just curl the safety wire into a hook shape, and then hook the wire through the holes in the bolts. Also, it helps to drill multiple holes in the bolt so that you have options when you go to wire it up. If you put 2 holes, 180 degrees from each other, you should end up with a convenient hole for each bolt.

It doesn't have to be perfect, and you don't have to have the wire going all the way through the bolt. If you just go through 1 of the holes in each bolt, it will be fine, they won't go anywhere.

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post #9 of 11 Old 05-01-2013, 01:28 PM Thread Starter
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Quote:
Originally Posted by kman0066 View Post
For the axle bolt, you can drill through at an angle, like this picture below. This is what I did to mine. Picture is from internet though:



For the pinch bolts, I just curl the safety wire into a hook shape, and then hook the wire through the holes in the bolts. Also, it helps to drill multiple holes in the bolt so that you have options when you go to wire it up. If you put 2 holes, 180 degrees from each other, you should end up with a convenient hole for each bolt.

It doesn't have to be perfect, and you don't have to have the wire going all the way through the bolt. If you just go through 1 of the holes in each bolt, it will be fine, they won't go anywhere.
Trying to figure out the best way to drill the axle at an angle. Did you drill with the axle in place (maybe loosen have it stick out a bit) or did you completely remove the axle?
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post #10 of 11 Old 05-01-2013, 01:52 PM
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Quote:
Originally Posted by brilliantspeed View Post
Trying to figure out the best way to drill the axle at an angle. Did you drill with the axle in place (maybe loosen have it stick out a bit) or did you completely remove the axle?
I did it with the axle in place. The metal is super soft (surprisingly), so a good punch will get you started well enough, then just be careful with the angle so you don't break through the corner.

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