Vintage Dirt Bike Q & A

I need a replacement fork bolt for my 1981 Honda XL100s but the problem is that this part is discontinued. I cannot find this bolt anywhere and I haven't been able to ride my bike for 2 years now because of this. The bolt is 22mm with a pitch of 1.02 please help me find this bolt or another solution to my problem. Thanks!

http://www.cmsnl.com/honda-xl100s-81-us_model7668/partslist/F++0701.html
This link will take you to the parts diagram for a XL100 '81 at http://www.cmsnl.com. I believe you are looking for part # 90116-383-721 and they have 2 in stock at Euro 3.00 which is about USD 6.00....

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

Wow you have no idea how happy I am now. thanks a bunch and that is not the exact thing i need but i looked on the site and the one I actually needed was right under it so thanks a million!

Well it seems as if I paid for a item they don't have in stock so I am still looking for one. Would it be possible to drill it out for a new size

If you are talking about the top bolt that holds your fork springs in place, I wouldn't think drilling it out would be a good idea to drill it out. I think I'd search and find a complete used fork or forks for this bike and either cannibalize the part or switch forks. What is the diameter of the fork where it goes through your triple clamps?? And the length of the fork? There may be alternative forks you could use. But Honda made a bunch of these bikes, I find it hard to believe there isn't a used fork or bolt out there somewhere.

Looks like that particular fork was unique to 81 and 82. But, if dimensions are same, forks from another year might work. doesn't look like you could use the fork bolt off of either of these, but the forks on one of them might fit your triple clamps.
This is off '84, and requires 27mm triple clamps: http://cgi.ebay.com/ebaymotors/HONDA-XR ... dZViewItem

Here is a set of '74 forks for $14.99. Don't know what size triple clamp fits it. http://cgi.ebay.com/ebaymotors/1974-XL1 ... dZViewItem

Ok my dad went to napa today and he ordered a oil drain bolt for a car that is the same diameter but the pitch on it is a 1.5 and on the actual fork bolt has a pitch of 1 will this work in anyway?

No. If you use a bolt with a different pitch to the hole, you will simply strip the threads of one, the other or both. I cannot believe your bolt is unique. Take it to one of those hardware stores that employee people who actually know something and match it to another bolt. You will need to know the M number which is the size of the shaft, the pitch - which we know is 1, and the length of the bolt. If they don't have it, but you can get those three dimensions, we'll find it on the Internet.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

it is 20mm in diameter, the pitch is 1, and the length looks to be around 30mm and believe me it is a unique bolt.

Try searching Google for "custom metric bolts"...let me know how it all works out.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

20-22mm is a pretty large bolt, almost an inch. Is this the nut that holds the triple clamp to the frame vs. a bolt?

At any rate, consider asking someone with a lathe to cut you a new bolt. It is time consuming but almost trivial for someone that knows what they are doing.

Rick

Yep, it would help all round to nail down the specific part. Honda normally states the dimensions of all bolts in their parts catalogs. I found numerous places on the web that will make a single bolt.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

I think what he's looking for is the we would call the fork cap,the one that holds the spring in.On these small Hondas it's threaded and called a bolt.I think the 73&74 CR 250s used threaded caps,but my MR uses a snap ring holding a cap with an "o" ring in place. He will have to get a part# and check Western Hills or ebay.

Don't put a 1.5 in a 1.0 try calling Western Hills Honda
call 1-513-662-7759 ask for Terry
He helped me find a bolt I couldn't find anywhere and had them in stock.

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Garry Mainer
#33m (retired)
Honda Cr250r 1980
Honda Cr250r 1980
Yamaha TY250C 1976
Arctic Cat 650 H1 2007

i talked to the tech school in my town and their teacher said they have a student who is a really big honda guy and he said if we have the original part he can make one to the exact specifications so that problem is solved!