Removing a nearly rounded allen bolt

[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?

[scumdog]

Could you tack-weld another bolt to it without burning anything??

[Maha]

You may have to hacksaw across it and use a flat head screwdriver.

[Gubb]

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

[Maha]

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

Yeah....and I know a good plastic welder up here for your pending cracked fairing....

[vifferman]

How tight is it? I'd try wedging summat in there, like an allen key and some tinfoil. Other options:
- Hammer an old screwdriver into the head.
- Use some strong epoxy such as JB Weld to glue an old allen key or somesuch in there.
- Drill a hole in it and use an Ezy-Out.
- Use a Dremel to cut a slot in the head, and use a slotted screwdriver.
- Grind the head off, then dribble WD40 or penetrating oil into the threads. Leave for a while and use locking pliers on the stub to turn it.

[breakaway]

Could you tack-weld another bolt to it without burning anything??

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

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

Didn't have any idea it was that simple, will give it a try later and post back.

You may have to hacksaw across it and use a flat head screwdriver.

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.

[Gubb]

As Maha said, be very careful about your fairing, last thing you need is a crack.....

[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.

[P38]

Pein the head around the hexagonal socket with a light ball pein hammer untill a new Allen Key wont fit.

Squirt some crc around it too

This will tighten the socket and loosen the bolt.

Tap the new allen key into the tightened socket and gently loosen the bolt.

Might have to do this a couple of times.

Becareful not to crack the faring.

Good Luck

[Spazm]

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

[westie]

Dude give me a call

[FLYMO]

hey being a metric bolt why not try a imperial allen key
they some times are a tighter fit
either that or get one of those torq fittings(star shaped) and wedge that in there
more bits biting in the better

[Zealot]

Try an impact driver? Although I'm guessing you don't have one...
If you do, whack something solid behind it, and beat the end of it with a hammer. Having a solid object (ie an anvil of sorts) behind it will stop it bouncing around and cracking the fairing.

Also try spraying with CRC a number of times.

Failing that, a drill always works.

[rok-the-boat]

Or, if it's clean, put the allen key in with a bit of that epoxy putty stuff, let it hardem, then turn it. Might be best to do it with a smaller size allen key to get more putty in. Never tried it - just thought of it.

Me though, I'd hit it at an angle with a small cold chisel to get it turning. Once you crack it free, it'll probably just unscrew with your fingers.