Intake Boots: 2 Questions

[sebring38]

RE: 82 GS850G
FIRST: I ordered new intake boots (engine side of airbox) and got 8 rubber O-Rings with them. It's obvious 4 go on flange which bolts to engine intake. Where do the other 4 O Rings go?
NEXT QUEST: In taking the old boots off one of the phillips screws that fastens the #3 boot to the engine intake twisted off: First the head, then the rest of the screw as I was "gently" trying to back it out with vice grips. Obviously, that screw is pretty tight. Can't get hold of it at all now. Any suggestions appreciated.

[DaveDanger]

Sebring, I'd say that they simply slipped up and shipped you two orderes of o-rings. Four is all there are. there ain't no more room for more Your next question is a bit more painful. Lemme ask if there is ANY of that bolt protruding from the head or is it pretty well gone flush or even recessed ?

[DaveDanger]

I'm trying to get you information as quickly as possible without typing a 45 minute post at my end... Have you tackled the remainder of those bolts yet? and if not, take some preliminary precautions... (Bolts or screws actually?) mine were phillips head screws. At any rate, if there is ANY difficulty in removing those bolts/screws, do not get drastic with the vise grips or such too quickly. Typically, the threads are simply dry and seized down in the head material. IF you have a friend handy, borrow help. to start with try a little shock therapy.. one person holds a good grip on the screw with modest turning torque (left-hand rotation) and the other person tap against the head of the screw with a hammer and flat ended punch if you have one. The combination of torque and impact will many times cause the screw to break loose. You can also not hurt anything by getting some penetrating oil into the picture either.

[DaveDanger]

If THAT fails, take a sharp tipped punch, and tap it into the edge of the head of the screw just enough to make it "bite". Then tip it over so that as you tap it, it is trying to turn the screw head in a loosening direction. If the screw begins to turn, change your punch angle to maintain the same drive, and continue tapping. Once you've gotten a quarter of a turn or so, it will usually spin out almost by hand, or at least easily by screwdriver. As for the one that's already reamed off... you MAY be able to do the same thing with the sharp punch I just described. a bit harder since you have less surface area to work with, but it can be done. IF that fails, you're pretty much down to drilling and extracting that broken screw. That's a whole 'nother post. Update us on what you have and any more we can advise you on.

[sebring38]

Thanks for the info on the O-Rings, will procede ahead, once I get that screw out. All of the screws came out with a little persuasion with hammer, screwcriver and liquid wrench. Will try Danger's idea of the punch. Ain't giving up yet. Just irritating when I was making good progress on the bike. Anybody heard of drilling a hole into the screw, tap out reverse threads and put a reverse screw in there to twist it out? I think I read somewhere about that, but wondering if anyone knows of a tool like that and where to buy...