Removing damaged bolt?

[Moleman]

Ok so went to start the bike today and battery was dead no big deal started fine with a bump and had a good ride of around 70 miles. I know the battery is fairly old and as it did not seem to be holding charge well I thought ok pick up a nw one which I did this afternoon. All well and went to fit it, one Allen bolt came out ok ish was very tight and already semi rounded but came out the other seat bolt was completely rounded and had a cut across the top of the dome so has been a problem to someone in the past I suppose.
Thing is I can't get it to budge at all. Tried to hammer in a slightly too big Allen key socket but didn't work and tried screwdriver socket to with a bit of force but still won't budge. Anyone any ideas to get it out without if possible cutting off the plastic infill panel? Bolt I can't get out is below

[Redmist]

You could try something similar to this method:

Watch from 8mins 30s:

E90IH20he80

[Moleman]

Didn't try that.. Will pick up a centre punch tomorrow and give it a try.. Looks simple why didn't I think of that! With the slot that's been cut in the dome I recon it might tap round.. Many thanks for the idea :-)

[Redmist]

Your welcome, hope it works!

[johnnyrod]

I've done that tons of times with nuts, screw heads etc., it'll work. There must be some reason the thing is jammed, maybe its threads are knackered, or the threads of the hole it goes into, or maybe it's just rusted to DEATH. You need the seat off to tip up the tank and other jobs so it's worth sorting out.

[Moleman]

It worked!
Bought chisel punch and few drill bits today and with a combination of drill and chisel it came out eventually. Had a good look at the bolt it was cross threaded and can't have been out for an age. Well it's out now and new battery fitted she started on the button. Threads have been re cut and confirmed working with the one bolt which was not distorted.
I have ordered a charger as well CTEK which seems to have some good reviews. Will fit the perminant connections when it arrives and it can tickle charge to its hearts content.. Thanks again for the pointers just need a couple of new bolts now.

[rickylp]

Good news! I've got a couple of fairing bolts and front mudguard bolts to try and get out as they are rounded off. Doesn't look like they've been out in quite some time! Could be quite troublesome I think as they are obviously recessed grrr:smt076

[Moleman]

This worked a treat for me and I thought yesterday I would be stuffed as just could not budge it. Was loosing my rag so just locked the garage and thought it better to pick some others brains I'm great full for the pointers I'm no mechanic but I do like getting my hands dirty and can turn my hand to most basic ish stuff but thought this bolt had me for a while. It was easier to get out being gentle rather than heavy handed, bit of patients seemed to have worked for me. Good luck with your fairing bolts I replaced mine not long after getting my bike as they let the bike down a bit. You might be surprised and they come out without too much grief. Good luck

[rickylp]

Cheers, if they weren't recessed I wouldn't be worried but I know they're going to be a right pain!

[Moleman]

Copious oamounts of wd40 and give it some time to seal in the be gentle if it don't work go have cup of tea and In my case about 6000 fags and try again but start gentle mine was a dome head and resesed but got there in the end