Removing a nearly rounded allen bolt

**rottiguy** · 22nd July 2008, 19:29

If the other end of the bolt is accessible you could grab it with vicegrips and turn it. Or try a flatblade screw driver and tap it into the widest bit and try turning. Or maybe superglue the allen key in and try turning once it has set.
That's my best guess without seeing it first hand. Good luck

Originally Posted by breakaway

Trying to remove fairing from my GSXR 600 today, and after removing all the bolts, I discovered that the last one was rounded! Looks like the prick that had it before me did it.

It is a 5mm bolt, one like this:

I don't think I am going to be able to get it out using any conventional means. It's so badly rounded that the allen key has absolutely no grip, it just turns.

How do I get it out?

**manicmedic** · 22nd July 2008, 19:58

No-one so far has surgested taking the bike to a dealer / workshop. Most I have found to be happy to lossen a bolt for a beer. If your g/friend can take it in ..... all the better.

Manic

**westie** · 22nd July 2008, 20:14

Bah slide it down the road.. It'll be off in a jiffy

**Max Preload** · 22nd July 2008, 20:54

Originally Posted by breakaway

How much for a decent hacksaw then? Don't want an asian brand. I'd like to purchase a good one that will actually last.

Just get a hacksaw BLADE. You'll only end up taking the frame off anyway because it'll get in the way. Pinch the blade between your thumb and first 2 fingers and gently drag it across the head to get it started.

Failing that, drill the head off using a drill the same diameter as the thread.

**Cruisin' Craig** · 22nd July 2008, 21:10

Originally Posted by Spazm

You could try an easy-out stud extractor if you have no joy with deforming it with a hammer

I second that. They've worked for me so far :-)

**birdhandler** · 23rd July 2008, 17:44

here you go Easyouts from jaycar 12 bucks last you a lifetime

http://www.jaycar.co.nz/productView....Max=&SUBCATID=

5 Piece Screw Extractor Set

Also known by the trade name of 'Easyouts', these are the only real way to get a completely stripped or mangled screw, bolt or stud out, even if the head has broken off completely. You simply drill a hole in what remains of the offending fastener, then use the appropriate size screw extractor with a tap wrench. They have an aggressive left-handed thread that bites into the metal, enabling you to unscrew the damaged fastener. This is the kind of tool you need once in a blue moon, but when you need them, they're indispensable.

• Sizes: 1/8", 5/32", 3/16", 1/4", 5/16"
• Case size: 120(W) x 120(H) x 15(D)mm

**P38** · 24th July 2008, 17:12

Originally Posted by birdhandler

here you go Easyouts from jaycar 12 bucks last you a lifetime

http://www.jaycar.co.nz/productView....Max=&SUBCATID=

5 Piece Screw Extractor Set

Also known by the trade name of 'Easyouts', these are the only real way to get a completely stripped or mangled screw, bolt or stud out, even if the head has broken off completely. You simply drill a hole in what remains of the offending fastener, then use the appropriate size screw extractor with a tap wrench. They have an aggressive left-handed thread that bites into the metal, enabling you to unscrew the damaged fastener. This is the kind of tool you need once in a blue moon, but when you need them, they're indispensable.

• Sizes: 1/8", 5/32", 3/16", 1/4", 5/16"
• Case size: 120(W) x 120(H) x 15(D)mm

Or untill they break

Wounder which will happen first?

**oldrider** · 24th July 2008, 17:24

Originally Posted by Max Preload

drill the head off using a drill the same diameter as the thread.

As Max Preload said, drill the head off remove the faring then fix the errant bolt when you can get at it more easily.

You may need to replace some of the faring screws you have taken out, to support the faring while you drill the offending screw head off.

If you don't know how to drill it out, find a friend who does. Good luck. John.

**scumdog** · 24th July 2008, 20:24

Be aware that SOME of those things are almost too hard to be marked with a hack-saw or file.

**Titanium** · 24th July 2008, 20:47

Get a torx bit one size up from the hex head and drive it in to the rounded out hole, will come out easy peasy. More points of contact. Use a socket to undo it.

The torx is tapered so easy to drive in and make tight.

Worked many times in the past.

To easy!

**westie** · 24th July 2008, 22:53

Originally Posted by breakaway

Don't have the skills or the tools for that

and I'm sure I'd melt some fairing in the process even if I did
Didn't have any idea it was that simple, will give it a try later and post back.
Might be time to buy a hacksaw! Can I just use screwdriver + hammer or would it be better to buy a hacksaw? With a limited amount of funds I'd really like to take the cheapest option out but don't want to fuck it up even more in the process.

Sooooo?? Did ya get it out or are you waiting to see how many different ways we can come up with?

**breakaway** · 25th July 2008, 11:08

Not yet, been busy with uni etc. (first week back) Matters are complicated by the fact that I don't have a drill etc, and I'm working heaps as well.

I'll probably get in touch with you sometime next week westie!

Edit: I did try metric keys, didn't have any luck though. It's well and truly fucked.

**westie** · 25th July 2008, 18:12

Originally Posted by breakaway

Not yet, been busy with uni etc. (first week back) Matters are complicated by the fact that I don't have a drill etc, and I'm working heaps as well.

I'll probably get in touch with you sometime next week westie!

Edit: I did try metric keys, didn't have any luck though. It's well and truly fucked.

Dude I went round morcs the other day and he was crying bout an allen bolt that wasnt ever coming undone, ever!
Had it un done in the time it took him to go get the tissues. We having biker shed beers night tonight come round if ya keen.(main focus on the beers tho) But could take your bolt off and replace it with another if ya want.