Solution To Undoing Suzuki Cheese Bolts!

Hi all,
After an off from a track-day, The peg was snapped off the hanger, and I bought a replacement hanger to solve the problem.

However! When trying to get the peg off... the allen key just chewed up the inside of the bolt with no way of getting it off.
Now, I've got myself another second hand peg off eBay, and before trying to undo it (as it's still attached to the brake leaver/hanger) I want to know if there's any known sollutions to getting them off with ease!

At present, the only solutions I've been told are
- Repeatedly spray WD40 onto it for several days
- To soak them in oil for a few days
- To heat the bolts up with a blow lamp just before trying to undo them

Anyone know if these will actually help? Or any other tried and testing methods? Thanks!

Drill it out and use a new bolt?

if its an allen key bolt, use a torx socket nes size up, bash it in with the good old trusy hammer, then that should work. if not drill it out.

also if you have a standard socket bolt/nut which is rounded off, try using an "E" socket. basicly the reverse of a torx. works wonders for rounded nuts and bolts. from any local halfords store

Originally Posted by riktherider

if its an allen key bolt, use a torx socket nes size up, bash it in with the good old trusy hammer, then that should work. if not drill it out.

also if you have a standard socket bolt/nut which is rounded off, try using an "E" socket. basicly the reverse of a torx. works wonders for rounded nuts and bolts. from any local halfords store

Had a Spark plug snap off flush with the cylinder head on a 2002 Ka recently and the garage used the above technique to remove it - worked a treat !

[northwind]

WD40's not a great penetrating oil, funnily enough, since it was designed as a water dispersal agent. Sikopen's good, but I like Plus Gas, it's a religion for me now

For that particular bolt, it's a bit tricky, you'll want a proper allen-key socket not just an allen key, and a really big ratchet or breaker bar, and a vise ideally. Most of the time when you damage these botls it's because they were stuck, and while you were trying to get it out you let the tool slip. It's pretty much inevitable when you're putting all of your effort into turning the bolt, and none into positioning the tool- a breaker bar will take away some of that element. It's a very shallow head as well, but of a sod all round.

And yep, heat is good too- that bolt's threadlocked and heat breaks threadlock down.

how much would it cost mr suzuki it put good quality bolts on in the first place?

Originally Posted by Banus

Had a Spark plug snap off flush with the cylinder head on a 2002 Ka recently and the garage used the above technique to remove it - worked a treat !

is the best way of taking anny rounded heads off. the amount of times i have had to use this technique because the bols on the sv are so sh1*e. swingarm bolt and nut BOTH rounded off (yes i am using good tools. very good tools. snap on as a matter of fact) just the fact that it is a 99 model, and the swingarm has never been taken off. used the e sockets for these. and also recently the cooling system drain bolt wouldnt come out, so tap on an e socket, and off it came! works a treat. heat works well, but i allways use it as a last resort.

problem is with buying better bolts, is that the company probably get other parts from the bolt supplier too and they have an agreement with the company to get other stuff too. had a big lecture on this sort of stuff last year. you would be surprised as well how much it would cost to get slightly better bolts too.

[northwind]

Originally Posted by kwak zzr

how much would it cost mr suzuki it put good quality bolts on in the first place?

Nothing. But it'd cost you There's actually nothing wrong with that particular bolt to be fair, it's just that it's threadlocked and never, ever gets undone except after a crash

Originally Posted by northwind

Nothing. But it'd cost you There's actually nothing wrong with that particular bolt to be fair, it's just that it's threadlocked and never, ever gets undone except after a crash

all the bolts are shi#? i wouldnt mind paying alittle more for a bike thats finished better.

[tigersaw]

Its nothing new, back in the 70's and 80's it was standard practice to remove all the fastenings and replace with an aftermarket kit containing the whole lot. The bike manufacturers back then didnt even use bolts, mainly soft alloy super cheesy buttery phillips head things.