Mr suzuki's cream cheese bolts

[kwak zzr]

:( i did an oil and filter on the gixer but one stubborn fairing bolt made my life a misery :( why is it i feel so down when that allen key spin all the way round :( anyhow for the past day or so i tryed everything to get this bu@@er out to no avail :( i have one trick left up my sleeve to get the sod out! whats ur experiences of cheese bolts?

[the_lone_wolf]

:( i did an oil and filter on the gixer but one stubborn fairing bolt made my life a misery :( why is it i feel so down when that allen key spin all the way round :( anyhow for the past day or so i tryed everything to get this bu@@er out to no avail :( i have one trick left up my sleeve to get the sod out! whats ur experiences of cheese bolts?

if you think fairing bolts are bad you should try the float bowl screws on a mikuni carb, not only are they japanese standard (JIS) heads, they're so soft you can actually squish them with a pair of pliers:o

[kwak zzr]

do the japs have plastic tools?

[kwak zzr]

arr got him out!!!! why it wouldnt budge i dont know? why do the easy jobs always turn out difficult?

[kwak zzr]

the offending rubbish OE part-
http://i86.photobucket.com/albums/k120/kwak-zzr/14022009085.jpg
http://i86.photobucket.com/albums/k120/kwak-zzr/14022009089.jpg
fixed with a good old proppa bolt!!
http://i86.photobucket.com/albums/k120/kwak-zzr/14022009082.jpg

[DarrenSV650S]

So what method did you use Kwak?

[kwak zzr]

i cut a slot in it with a dremel and used a screwdriver with a spanner on for leverage

[dizzyblonde]

ummmm somebody once tightened the air filter in so tight, that my ickle hands couldn't undo it....I had to get nasty with a dremel, and cut a slot for a flat head.

were yours made out of Philadelphia Kwak?

[kwak zzr]

they were! ruddy rubbish! bad really for a 18month old bike with only 3k on the clock.

[dizzyblonde]

poor kwak
cheer up it could be cottage cheese :-)

http://www.youtube.com/watch?v=ht1vouSNy4I

[Sid Squid]

I don't know why but I very very rarely have problems removing nuts and bolts on a Japanese bike, or any other kind for that matter, no matter how old.

[Stu]

I don't know why but I very very rarely have problems removing nuts and bolts on a Japanese bike, or any other kind for that matter, no matter how old.
Does that only extend to bikes you own?

:smt090

[shonadoll]

My bar ends went soft and I had to drill them out and replace them.

[G]

I don't know why but I very very rarely have problems removing nuts and bolts on a Japanese bike, or any other kind for that matter, no matter how old.


I would agree, the only time I have ever had problems is when I use the wrong tool because I dont have the right one.

That bolt that is pictured should be literealy almost hand tight, it was probably done up to tight at one point.

[xXBADGERXx]

If the Allen key is starting to deform (I open them slowly you see) then remove the key from the cap/button head bolt . I put a pin punch on the end of the bolt and give it a short sharp shock with a hammer . The deformed bolt has basically lost it`s ability to maintain any solid shape anyway . The shock may help persuade the bolt to open . The deformed head will have peened back into shape and you may need to lign up the allen key and give it a tap to get it back into the head of the bolt ....... try it again . Chances are that it won`t undo anyway . I use Plusgas on bolts like this and it works a treat . WD40 is not as good as Plusgas for undoing bolts as it penetrates but for some reason it dries up and doesn`t leave a thick enough lubricating film . With really stubborn bolts it`s best to undo them half a turn the go back in again , if you just unwind them right out the corrosion can grind away from the threads and form a hard compressed nugget which can strip a thread on the way out if bullied . My rule of thumb here is if you are thinking about wincing or grunting or giving it a bit of welly then something is wrong and lubricate and wind back in and out again .

Of course there will always be a bolt that , under no corcumstances , will want to play by the rules . I have one holding a bobbin in on my swingarm and it`s a Horror I can tell you , not even Plusgas and Stilsons will make that puppy move . On a nice day I am going out there with different sized drills and I am going to drill the core of the bolt out as close to 8mm as I can get without touching the thread then I am gonna Plusgas it and use a stud extractor .

I always replace my bolts with Stainless ones as I go along and use some Blue Loctite that looks like a glue stick . I put the bolts back in without overtightening and the Blue Loctite gives it a little extra resistance to coming undone without having to overtighten them .

[John 675]

ahh the cheesium alloy factory.. located directly opposite suzuki japan lol for all your cheesium needs!

[muffles]

I just remembered one tip I have for undoing them without wrecking the heads - it's not for when the bolt is done up too tightly, but for when the force you need will damage the head. I just use an allen key and a rubber mallet and tap it round. Many taps from the mallet seem to be better for distributing the force and preventing damage, than 'leaning on it'. I've got an allen key socket set which would enable me to lean on it with a lot of force so I've tried the alternative!

[kwak zzr]

for some reason this one was mega tight and what made it more difficult was the fact it was against my fairing panel and i couldnt grip the outside of it at all, anyhow today every bolt i can see is coming out and being copper greased!

[kwak zzr]

I've got an allen key socket set

this is the type i use.

[muffles]

this is the type i use.

It might be a bit heavyweight is what I was thinking, hence try the allen keys and tapping the end with a rubber mallet. It's worked for me anyhow :D

[skyline]

Yeah I've got a spare set of sv carbs at the mo (rejet practice!) and one of the float bowl screws is seized on that...I used an impact driver screw bit on a ratchet which did the trick on all the other bolts but this particular one it rounded off...

I've been trying to use a small hacksaw to file a flathead slot but may well end up getting a dremel or a screw extractor set. The carbs are in my living room tho, a dremel would end up sending sparks everywhere wouldn't it...?:shock:

[kwak zzr]

wouldnt matter anyhow i had sparks up my fairing but it didnt damage the finish at all, cutting a slot if possible is a good idea but if the bolts small it may well just chew the head off.

[the_lone_wolf]

wouldnt matter anyhow

i wouldn't want to be showering sparks on the carpet and sofa...:o:o

the dremel will do the screw head in seconds, that's how we eventually got the last one off the float bowl of the DRZ carb - thankfully thumpertalk do a set of allen head stainless bolts to replace them with which are much better

[skyline]

Heh heh with them sparks a dremel's not a good idea then!:p
Looks like a screw extractor set for me then...

[zsv650]

for all this moaning about suzuki bolts and fasteners has anybody thought about going in to a suzuki main dealer's and raising the issue direct with them even send something to suzuki japan itself stating that everyone's ****ed off with the crappy bolt's.

[Gene genie]

should've bought a honda kwak.

[shonadoll]

should've bought a honda kwak.

They are not immune to this either-on another forum I'm on theres a guy getting people together to make a claim against Honda for corrosion issues.

[Shellywoozle]

should've bought a honda kwak.

And sell the gixxer to me :p

[Gene genie]

And sell the gixxer to me :p
do you want the shirt off his back too?

[Shellywoozle]

do you want the shirt off his back too?

Nah wouldnt fit me, gixxer willl do LOL

[kwak zzr]

i did went the honda route with my cbr600fw good bike and the finish is better but i got bored and sold it :)

[yorkie_chris]

Of course there will always be a bolt that , under no corcumstances , will want to play by the rules . I have one holding a bobbin in on my swingarm and it`s a Horror I can tell you , not even Plusgas and Stilsons will make that puppy move . On a nice day I am going out there with different sized drills and I am going to drill the core of the bolt out as close to 8mm as I can get without touching the thread then I am gonna Plusgas it and use a stud extractor .

I always replace my bolts with Stainless ones as I go along and use some Blue Loctite that looks like a glue stick . I put the bolts back in without overtightening and the Blue Loctite gives it a little extra resistance to coming undone without having to overtighten them .

For first part, if it is a through hole then the bolt may wind out as you drill through.

For the second, I think loctite interrupts the corrosion, so locking the fastener and preventing it siezing too. Cool.