Bolt problem

[mylovelyhorse]

Afternoon all,

I am just getting on with swapping out the gearbox on my 1999 R1150GS (what a job!) and have encountered a little problem.

The bike is fitted with a Remus end can and also a y-piece to get rid of the cat. There are two taper headed bolts that hold the y-piece to the bike. One of the b*ggers has a rounded off allen head - a kind gift from the DPO.

Any suggestions for a good way to get it out & does anyone know if replacements can be obtained?

Cheers

 

[RickG]

In some kind of order of desperation:

Firstly leave to soak overnight in WD40 or better

I think I'm right in saying it's no use drilling just the head off as it'll still leave a chunk of bolt in the frame?

Can you get just that part of the remus hot without doing any damage to the bike? The previous owner may have loctited it in.

Use a nice sharp center (dot) punch on the edge of the head of the bolt to knock it round anticlockwise, once (if) it shifts a quater turn, the allen key may still fit well enough to finish the job.


Drill down the center of the bolt a hole with the same diameter as the bolt itself (Looks like an M8?)This is a bit tricky as you need to keep the hole dead-central to avoid damaging the surrounding bits of bike, and allen bolts are usually quite hard. However, you don't need to go far, just enough to drill out the bolt past the frame and just into the remus. At that point, in theory, the two should no longer be connected


As for replacement bolts, any decent engineering suppliers will have them, just have a look in yellow pages.

Good luck!

 

[Steptoe]

Hit with an oversized torq bit -works everytime

 

[motobiker]

Hit with an oversized torq bit -works everytime

 

[mylovelyhorse]

Hit with an oversized torq bit -works everytime

Damn that's clever

 

[mylovelyhorse]

Well, I tried that today and it didn't work, which is a bit of a bummer.

More pics at http://www.flickr.com/photos/mylovelyhorsie/?saved=1 if anyone's interested.

Tomorrow I go for the centre-punch, blow-torch and lotsa heat route. After that, dunno.

 

[vilguy]

Simply use a stud extractor, couple of quid, its like a corkscrew sort of, you will need to drill a guide hole for it, and then screw it in anti clockwise, as you screw the threads will cut into it and eventually the force you exert on screwing it in "should" be more than that retaining it, and it "should" extract. Do yourself a favour though, dont shear it off in the hole or yea gods will you be miffed. Theyre 'ard as fook and yourll bugger up a dozen drills before you get it out.

 

[brucewayne]

Simply use a stud extractor

The devils work

 

[DrFarkoff]

They are the concial bolts with the torx socket in them

It's just into the crossbar of the catalytic convertor just carefully drill the feckers out they are just standard bolts and not high tensile

Start small and plenty of lube and keep the drill steady and don't break it once you get to the size of the bolt shaft or near the head should come off and you can drill the rest of the bugger and then retap it!on the bench!

 

[vilguy]

They are the concial bolts with the torx socket in them

It's just into the crossbar of the catalytic convertor just carefully drill the feckers out they are just standard bolts and not high tensile

Start small and plenty of lube and keep the drill steady and don't break it once you get to the size of the bolt shaft or near the head should come off and you can drill the rest of the bugger and then retap it!on the bench!

Id actually do this, itll be easier, and stud extractors are easy to break if you havent used them before.