Help O Sage Ones, Rounded Bolt Removal

[spyug]

I'm not an expert, but i've always been told not to weld anything on a bike if the wiring harness and electricals are in place. You stand the chance of frying all the delicate stuff.

Just something to think about. Anybody else hear of this?

Good luck with this problem.

cheers,
Spyug.

[uudfourty]

sounds to me like my suggestion-- high explosives-- would be your best bed for successful bolt removal. unfortunatley, everything else would be removed or... displaced... along with it.
depends on how much of a grudge you have against that bolt.

[marvinsc]

sounds to me like my suggestion-- high explosives-- would be your best bed for successful bolt removal. unfortunatley, everything else would be removed or... displaced... along with it.
depends on how much of a grudge you have against that bolt.

Since it'a a through hole with a nut on the other side I'm going to try a specialty socket first and if it rounds on off I'll cut the head off with a Dremel.

[earlfor]

If that engine mount plate is like every other one I have seen on a GS, that "nut" on the backside is welded to the plate. Cutting off the bolt head will leave you no means of removing the bolt. I would cut a slot in the bolt head with a dremel using a cutoff disk and then use an hammer impact driver with a straight bit.

Earl

Since it'a a through hole with a nut on the other side I'm going to try a specialty socket first and if it rounds on off I'll cut the head off with a Dremel.

[marvinsc]

It actually is a Nut Earl, it's really tight and I can't get a wrench on it. I got the one on the Right side by Locking some long nose vice grips on it while I turned the bolt. The bolt on the Left started trying to Round off almost immediatly, I suspect it's Less that grade 8 hardware. I do like the Impact idea if the specialty socket doesn't work.

[marvinsc]

Problem Solved! I picked up a set of Irwin Bolt Grabber sockets at Advance Auto parts and It came Right out. The head was almost completely rounded off but the socket has reverse ridges that grab whatever is there. $22.98 I don't regret spending at all! :-D

[chef1366]

Problem Solved! I picked up a set of Irwin Bolt Grabber sockets at Advance Auto parts and It came Right out. The head was almost completely rounded off but the socket has reverse ridges that grab whatever is there. $22.98 I don't regret spending at all! :-D

I'll put the fire out. :-D

[earlfor]

I think I have worked on every GS model except shaft drives and the 550.
I've never seen one that had loose/unwelded nuts on the engine mount plates. Go figger. :-)

Earl

It actually is a Nut Earl, it's really tight and I can't get a wrench on it. I got the one on the Right side by Locking some long nose vice grips on it while I turned the bolt. The bolt on the Left started trying to Round off almost immediatly, I suspect it's Less that grade 8 hardware. I do like the Impact idea if the specialty socket doesn't work.

[marvinsc]

I think I have worked on every GS model except shaft drives and the 550.
I've never seen one that had loose/unwelded nuts on the engine mount plates. Go figger. :-)

Earl

This bike probably has a lot more in common with Your Bandit that any of the Gses. My understanding is that the shaft drive system is the same One as the Cavelcade.

[earlfor]

Thats what I get for just dropping in at the last post in the thread and not reading the whole thing. I assumed getting a bolt loose wouldnt matter whether it was on a motorcycle or a washing machine. eheheh Apparently that doesnt hold true. :-) Glad ya got'er loose. Yeah, that engine does remind me of the Bandit.

E.

This bike probably has a lot more in common with Your Bandit that any of the Gses. My understanding is that the shaft drive system is the same One as the Cavelcade.

[Shin-Ken 1074]

Hi marvinsc,
Iam new to the forum (last week) and am working my way through the posts to see catch up on things. Glad to see you've fixed the rounded nut problem. It is a bit late now however, another way to remove rounded nuts or captive bolts is to tap them off using a good quality cold chisel. I don't mean cut them off, place the edge of the cold chisel against the remains of the nut and tap it gently anti-clock wise with a hammer. Have used it with success on lots of damaged, rusted and butchered nuts and bolts, even the 6mm phillip head screws that hold the oil screen case in the sump of my GSX1100SXZ. Its a one way ticket, their no moviestar when its done but you'll have those stubborn little cheese headed things off.

Shin-Ken 1074

[Zooks]

cheese headed things????

[gsgeezer]

You can cut a slot in it and use a big screwdriver.

[marvinsc]

Hi marvinsc,
Iam new to the forum (last week) and am working my way through the posts to see catch up on things. Glad to see you've fixed the rounded nut problem. It is a bit late now however, another way to remove rounded nuts or captive bolts is to tap them off using a good quality cold chisel. I don't mean cut them off, place the edge of the cold chisel against the remains of the nut and tap it gently anti-clock wise with a hammer. Have used it with success on lots of damaged, rusted and butchered nuts and bolts, even the 6mm phillip head screws that hold the oil screen case in the sump of my GSX1100SXZ. Its a one way ticket, their no moviestar when its done but you'll have those stubborn little cheese headed things off.

Shin-Ken 1074

I'm familiar with the method but in this case there would be No way to access it with a cold chisel. Had the specialty socket failed I was prepared to start on it with a Dremel.

[Shin-Ken 1074]

Yes, cheese headed things. Some of the phillip head screws and bolts can't have too much steel in them considering how soft they can be. So it seems that some screws and bolts must have a high cheese content to make them so soft and easy to round off, its not the user its the material.