Bolt removing help

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22 May 2004
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Hi guys I am stuck at the moment removing Bolts from my bandit.

There are 8 bolts on the downpipes which connect the don pipes to the engine. I have managed to remove 3 of them but the other 5 are stuck.

The bike is 2nd and I think the bolts have been reused since they are in a bad state. They are 6mm hex/allen keys.

The ones I am trying to get out as soon as you turn the head it just spins since they are rusted so much.

I have tried a driver. Heating them and all. Anyone got any ideas. I would take them out with a spanner but the head is round.


Gareth
 
Dunno what sort of clearance you have there, but ive seen a few grease monkeys hammer a socket just smaller than the head of the bolt/nut and take it off that way...

Beware though, your socket will be wrecked SnapOn or not! :P
 
if you have access to a welder then weld a short bar on to give leaveridge.(sp) or use a small chisel to tap them round, or failing that, grind or chisel the heads off and fetch them out when the exhaust is off. or bit brutal but knock a smaller socket onto the outside of the bolt and wind them out. :eek:



beaten to it...
 
The OP clearly stated that they are socket headed bolts (i.e. use allen keys) so whacking an undersized socket over then is unlikely to achieve nothing other than breaking the socket.

I would first liberaly soak them in a decent penetrating oil (plus gas etc.) and leave overnight preferably. If the hex has rounded, then carefull application of a punch and hammer can deform the bolt head enough for the allen key to get some purchase on. In any case, giving the bolts heads a good whack with a hammer helps to break any rust that is seizing the bolt. As said above, if there is no way an allen key will grip, and presumably there is no room for mole grips, then use a cold chisel to try and rotate the head.

On trick I have used is to use a dremel with cutting disk to cut a screwdriver slot, and then use a decent quality screwdriver that has provision to use a spanner on the shaft to get a decent amount of leverage.

Heat can also help greatly to release stuck fasteners. Use a blow lamp and get the fastener nice and hot (but obviously be carefull of damaging cylinder head). Welding e.g. a nut or bolt onto the head of the fastener nearly always works due to the heat generated (and of course the fresh hex head).

Cutting the head of the bolt off is last resort. If you can't remove the bolt using the small stub that is left after this operation, then you have little choice but to get the remains drilled out and possibly helicoiled, depending on any damage to the threads.
 
Dogbreath said:
The OP clearly stated that they are socket headed bolts (i.e. use allen keys) so whacking an undersized socket over then is unlikely to achieve nothing other than breaking the socket..

That is exactly how I removed the locking wheelnuts off my car when I discovered that the 'key' was missing for them, worked a treat.

I'd agree with you that if possible the best way is to weld a bolt into the head of them for two reasons, The bolt will give you a 'fresh' hex head to get extra power on the bolt and the heat of welding it will destroy any corrosion bond or threadlock that might have been used.
 
Have you tried taking them out when the engine is hot? Watch your fingers though :eek:

Loads and loads of WD40 soaking for a few days will help too.
 
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