striped bolt

went to remove my lower fairing and hugger and the allan key bolts are rounder has anyone got any ideas how to remove them rear hugger is the center one next to rear shock any help would be greatful

[Blue Flame]

Re: striped bolt

Thought that this was a post about some new type of zebra bolt for a minute

If I am understanding you correctly you have knackered the allen key bolt and allen keys are now just turning freely instead of undoing the bolt ?

If so it seems that you need to buy one of these bolt extractor jobbies (a wee tool with a left hand thread that dirlls into the knackered bolt) to get the bolt out. They are not dear I believe. I have seen them on e-bay at much cheapness prices. Don't know about the quality though.

Grab it with some mole grips/small stilsons if you have access

Get someone to MIG a bolt onto the head

Get a slightly large allen key and bray it in

Whatever you do good luck and be carefull

Tris

[timwilky]

Firstly Jeeze these bolts shouldn't be that tight that they would knacker the heads trying to undo them.

I read a lot of complaints of Suzuki bolts being cheese like but to be honest I have never experienced any problems. I do replace bolts I remove with stainless. The only ones I experienced problems with where the bolts that secured the subframe plastics and they had been grollied by the previous owner.

Are you using "Cheap" allen keys?. if so throw them away and buy a decent set. The bolts you are referring to (on my bike) are 4mm. Use a wrench allen key. and hammer it as deep into the bolt head as you can. if that don't work assumming the head is well rounded drill the head a bit deeper and hammer in a torx bit. I would suggest using an 11/64" drill bit and a T27 start swaging a torx head then a T30 torx bit. If that dont shift it then you are going to have to drill the heads off.

By just drilling the head off, you can them remove the plastics and there should then be enough meat left to grip with a good set of mole grips or small stiltsons after leaving the offending bolts soaked in plus gas overnight.

Avoid resorting to extractors, in my experience they are the last resort. I would prefer to drill as close to the bolt root diameter as I can and using a very fine chisel tap the offending bolt away from the thread it is siezed in.

OR if you can get in with a junior hacksaw saw a groove throught the head of the bolt about 4mm deep then the groove the cut has left put a flat headed screwdriver into is and try unsrewing it.

If you mean the dome head style I work with this type of bolt on a regular basis and i've found that if you can get to it they do come loose with a centre punch and hammer just tap it around but make sure you don't hit it to hard or miss

first thing i would do, is go and buy another set of hex keys,

the keys often round before the bolt itself.
but you cant really see the hex key being rounded, as it is only slight.
or try using a grinding agent in there, (autosol is pretty good believe it or not)

ensure that you are using the right size (imperial and metric are different)
i believe the SV uses metric keys, but i could be wrong.

if that fails, get a flathead screwdriver bit, and gently tap it into the metal, enabling you to use a flat head screwdriver to get at the bolt,

or try getting at it from the other side, getting some mole grips on it and twisting it out.

or get a set of stud extractor drill bits and go at it, but if your going to be drilling, you might as well just drill the thing out and get a new set of bolts.


and for everyone who moans that the suzuki bolts are bad, go to BandQ, they sell a huge range of bolts in all different sizes and types, very cheap indeed.

(i got a pack of 10 bolts for my master cyclinder for less than a quid, where as my dealer wanted 3 quid a bolt)

I got a pack of 5 bolt/screw extractors from screwfix for just over 4 quid. They are like drill bits but the thread runs the wrong way......looks easy enough and will be trying out this weekend

so hows it going ?

got em off yet ?

Be V careful with stud extractors.

Ther are made of hardened steel and if you snap one of them in place you won't be drilling it out