help to remove rounded allen bolt - Steve Saunders Goldwing Forums

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post #1 of 12 (permalink) Old 08-12-2007, 01:34 PM Thread Starter
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:Pok ive been a little heavy handed and rounded a Allen bolt, one of the four Allen bolts that hold the front fender in place refused to move, and i have rounded it!!!! has anyone got any tips on how to remove it please, by the way, it sits into a slight recess in the fender, so you cant get a grip on the sides, all the best pp

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post #2 of 12 (permalink) Old 08-12-2007, 02:26 PM
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mig weld an allen key into the bolt and unscrew, bolts u/s and easy outs just break, arc welding will melt plastic guard mig should be ok if cooled as soon as welded

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post #3 of 12 (permalink) Old 08-12-2007, 02:29 PM
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Drill it and use an EZ-out to extract it if the diameter is big enough. Soak it in penetrating oil prior to using the extractor and it will be easier and less likely to break the smaller extractor.
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post #4 of 12 (permalink) Old 08-12-2007, 02:35 PM Thread Starter
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many thanks, ill try the drilling method first , rather than risk the heat near to the plastic fender, thanks

Graham nsu quickly, suzuki 50, yamaha fs1e, yamaha 250yds7,
triton 750, trident750t150, norton commando 850 roadster,
honda750 f1, honda 750 f2, honda gl 1100, bultaco 250, kawasaki 500 h1, jpn commando ,25yr gap
2001 gl 1800 love it
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post #5 of 12 (permalink) Old 08-12-2007, 05:49 PM
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pinkpork wrote:
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many thanks, ill try the drilling method first , rather than risk the heat near to the plastic fender, thanks
Just be sure to let it soak in penetrating oil. Over night is best. If not, the risk of breaking the EZ-out is greatly increased, especially with one this thin.
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post #6 of 12 (permalink) Old 08-12-2007, 05:54 PM Thread Starter
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ill do as you saymany thanks pp

Graham nsu quickly, suzuki 50, yamaha fs1e, yamaha 250yds7,
triton 750, trident750t150, norton commando 850 roadster,
honda750 f1, honda 750 f2, honda gl 1100, bultaco 250, kawasaki 500 h1, jpn commando ,25yr gap
2001 gl 1800 love it
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post #7 of 12 (permalink) Old 08-12-2007, 06:25 PM
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I have had luck in the past using a cutting wheel on my dremel to cut a slot thru the head of the bolt and using a slotted screwdriver to get it out.

Ifyou can get at it use one of those hammer driven impact drivers to crack it loose.

Good luck

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post #8 of 12 (permalink) Old 08-12-2007, 06:46 PM
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Might not even need a cut slot..... use a allen head socket on your impact driver and tap forcefully..... may come out...... you'll need a new allen bolt, but, you need that anyway! Good luck,

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post #9 of 12 (permalink) Old 08-12-2007, 07:22 PM
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If this is where I think it is, you can't use heat or any pounding there anyway and you will not get a drill in there either.

I would waste the chrome fork cover as they are cheap enough and I would cut a slot across the head with a Dremel and a cutting disk.

Then I'd use a ratcheting right angle screwdriver with the large blade in it and wrench them out.







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post #10 of 12 (permalink) Old 08-13-2007, 04:45 PM
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When I rounded out the allen bolt on the fork bottom, I was able to remove it using a left handed drill bit. I was prepared to drill the entire head off if need be, but before that happened it finally loosened and spun out.

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