ZX 9 still running rough.

Got most of the fairings stripped off. Now does anyone know a good way to remove seized bolts? I can't get the right side fairing, belly pan or tail off due to seized bolts. Doesn't help that they were already pretty much rounded off from the last owner.

After removing the nose and all the ram-air ducts I found some of the worst wiring I have ever seen. Whoever fitted the gear indicator and heated grips obviously didn't know how to do it properly. They have spliced the heated grips and gear indicator into the front headlight wiring and clocks by using glue from a glue gun to bind them together and then didn't even cover them over with tape. So I've removed the gear indicator and the wiring from the heated grips and will repair the damage this week.

This is how far I got before I packed everything away today.



I'm thinking of getting some new indicators as well as I've somehow lost the plastic cover off one of the front indicators. May also replace the rear tail light with an LED one depending on how much they are.

I've managed to get the lower fairings off now by removing the mounting brackets which hold them to the engine case.

The bolts holding the fairing to the brackets are rounded off and possibly seized. What would be the best way to remove them? I would have normally thought heat but that would damage the fairing.

I've also got a seized cross head bolt on the tail which just won't budge and I can't get any grip on it as it was so chewed up from whoever last tried removing it that I'm just chewing it up even more.



Any tips on how to remove these would be appreciated. Thanks

[maviczap]

Drill the head off it carefully, once you've got the fairing off, grab the stub with some grips, but treat the stub to some Plus Gaz

Thanks. I'll give that a go tomorrow.

[Sid Squid]

Get a flat head punch about 1/4" and carefully reform the head of the screw. The action of whacking the end can help in shocking the screw free, and if you're careful you can make the screwdriver fit in the screw much better.