I have stripped & now broke bolt's how to remove ? help. - Discuss I have stripped & now broke bolt's how to remove ? help. on CBRXX, the ultimate on-line community for Honda motorcyclists. Read it in Body / Paint / Electrical / Lights. (Discussion of Honda CBR 1100 XX Super Blackbird Bodywork, Seats, Seat Cowls, Paint, Windscreens, Electrical System, and Lights.)

fzrcbrklxrider · 04-22-2007, 7:09 PM

I have 3 rounded/stripped allen bolt's that hold the side panel fairing's in place, i have no experience with stripped allen head bolt's anyone got idea's on how to remove without destroying the fairing's

, please help, Thanks

XXNUTZ · 04-22-2007, 7:15 PM

In my experience as an automotive tech, now an instructor, I have had success with lightly tapping a TORX bit just a bit bigger than the allen head into the bolt. Don't know if this will work on the 'Bird. Good Luck!

shovelstrokeed · 04-22-2007, 7:35 PM

You might start by buying a new hex wrench and then getting some valve grinding compound (the coarse stuff). Smear it on the wrench and in the hole.

Most of the time, the rounding of these shallow wrench depressions is caused by a poorly fitting, worn hex key. Get a good one.

redxxrdr · 04-22-2007, 8:50 PM

Try a new wrench first. I did the same recently and removed mine with reverse rotations drill bits and a easy out. Fastenal has a nice set, but they are pricy.
I would suggest getting new ones once you get them out. Once stripped, they will be loose on the wrench forever.

phillips2DAMAXX · 04-22-2007, 9:10 PM

FZRCBRKLX Rider,
I had the same problem. Here is how I solved it. Put some PJ lube or liquied wrench on the allen bolts. Then use an all, or pontend puch and use the dimples around the perimiter of the bolts and tap then in a counter clockwise dirrection. I did this and the tapping motion lossend them right up. then use the new allen wrench. Just be carful not to slip and scratch your fairing.

Good luck,
Scott

fzrcbrklxrider · 04-22-2007, 10:02 PM

Quote:

Originally Posted by phillips2DAMAXX

FZRCBRKLX Rider,
I had the same problem. Here is how I solved it. Put some PJ lube or liquied wrench on the allen bolts. Then use an all, or pontend puch and use the dimples around the perimiter of the bolts and tap then in a counter clockwise dirrection. I did this and the tapping motion lossend them right up. then use the new allen wrench. Just be carful not to slip and scratch your fairing.

Good luck,
Scott

Thanks for all the great idea's I actually used 2 new allen wrench's with no luck the hole's are rounded completely mostly caused from the previous owner over tighting them but, I should definately be able to get them out now, Thanks again all

, Matt

slyxdevil · 05-03-2007, 10:36 AM

when easy out failed me i once welded a nut on to it that did the trick

erlingj · 05-03-2007, 11:16 AM

Quote:

Originally Posted by XXNUTZ

In my experience as an automotive tech, now an instructor, I have had success with lightly tapping a TORX bit just a bit bigger than the allen head into the bolt. Don't know if this will work on the 'Bird. Good Luck!

fzrcbrklxrider · 05-03-2007, 6:15 PM

I used the small punch method, But I ended up breaking 1 bolt head off leaving the thread's inside the frame, any suggestion's I will probably drill it out & re-tap to a larger thread since it is aluminum, I dont think I can get it out with a easy-out it is in there tight & I beleive I messed the thread's up when trying to remove it once already with the same punch (bad idea) oop's darn what to do ? thanks everyone.

MuayThaiFan · 05-09-2007, 4:59 AM

Quote:

Originally Posted by fzrcbrklxrider

I used the small punch method, But I ended up breaking 1 bolt head off leaving the thread's inside the frame, any suggestion's I will probably drill it out & re-tap to a larger thread since it is aluminum, I dont think I can get it out with a easy-out it is in there tight & I beleive I messed the thread's up when trying to remove it once already with the same punch (bad idea) oop's darn what to do ? thanks everyone.

How did you mess up the thread with the punch? You're supposed to angle the punch into one of the side holes and just give it light taps in a counterclockwise direction.

But since it's already done, I don't suppose you can apply heat can you, since it's near the fairing? If the stud is exposed and you can get a vice-grip on it, try to grip it and turn it out. There's no more locking pressure on it since the head is already broken off.

If not, get a hacksaw or dremel tool to it, you can saw a notch then turn it out with a flat head screwdriver, after applying copius amounts of WD-40

If not, then use a drillbit smaller than the diameter of the stud, set it in reverse (counterclockwise), counterpunch a hole on the stud, then slowly and carefully drill it. It should come out with the drilling, if not, insert an Ezy-out and screw it out. That's your only option now that the head is snapped off.

MuayThaiFan · 05-09-2007, 5:00 AM

If you're not confident of the job, I'd seriously suggest riding the bird down to a competent mechanic and have him do it for you. Seriously, you could end up damaging your paint work or fairing, then it'll really get expensive.

rosanne · 05-09-2007, 7:21 AM

Don't know where the Allen bolts are but you could use a cutting disk to put a cut in the top of the bolt and use a blade screwdriver or impact blade to get it out

XXMAN · 06-12-2007, 11:25 AM

BUY A SCREW EXTRACTOR SET FROM HARBOR FREIGHT OR SEARS.

fzrcbrklxrider · 06-12-2007, 1:47 PM

I was going to buy a left handed drill bit & screw extactor, but the screw&thread's were damaged beyond repair. I ended up drilling out the broke-off screw, & threaded the hole, aluminum is alot easier than steel IMO.

04-22-2007, 7:15 PM	#2
XXNUTZ Flyin' Lo and Free Join Date: Mar 28 2007 Location: South Elgin, Illinois Age: 43 Posts: 548	Re: I have stripped fairing allen bolt's how to remove ? help. In my experience as an automotive tech, now an instructor, I have had success with lightly tapping a TORX bit just a bit bigger than the allen head into the bolt. Don't know if this will work on the 'Bird. Good Luck!

04-22-2007, 7:35 PM	#3
shovelstrokeed Join Date: Dec 16 2006 Location: S. Fla Posts: 302	Re: I have stripped fairing allen bolt's how to remove ? help. You might start by buying a new hex wrench and then getting some valve grinding compound (the coarse stuff). Smear it on the wrench and in the hole. Most of the time, the rounding of these shallow wrench depressions is caused by a poorly fitting, worn hex key. Get a good one.

04-22-2007, 8:50 PM	#4
redxxrdr Craig Join Date: Nov 21 2006 Location: Sumner, Ga Age: 51 Posts: 315	Re: I have stripped fairing allen bolt's how to remove ? help. Try a new wrench first. I did the same recently and removed mine with reverse rotations drill bits and a easy out. Fastenal has a nice set, but they are pricy. I would suggest getting new ones once you get them out. Once stripped, they will be loose on the wrench forever.

04-22-2007, 9:10 PM	#5
phillips2DAMAXX Join Date: Mar 14 2007 Location: Flower Mound, TX Posts: 68	Re: I have stripped fairing allen bolt's how to remove ? help. FZRCBRKLX Rider, I had the same problem. Here is how I solved it. Put some PJ lube or liquied wrench on the allen bolts. Then use an all, or pontend puch and use the dimples around the perimiter of the bolts and tap then in a counter clockwise dirrection. I did this and the tapping motion lossend them right up. then use the new allen wrench. Just be carful not to slip and scratch your fairing. Good luck, Scott

05-03-2007, 10:36 AM	#7
slyxdevil Join Date: May 02 2007 Location: sussex nj Posts: 228	Re: I have stripped fairing allen bolt's how to remove ? help. when easy out failed me i once welded a nut on to it that did the trick __________________ hard to steer when the devils driving,brakes who needs em they only slow you down NOW ROCK ME UP TO 135!!

05-03-2007, 6:15 PM	#9
fzrcbrklxrider Join Date: Apr 08 2007 Location: Texas Posts: 209	Re: I have stripped fairing allen bolt's how to remove ? help. I used the small punch method, But I ended up breaking 1 bolt head off leaving the thread's inside the frame, any suggestion's I will probably drill it out & re-tap to a larger thread since it is aluminum, I dont think I can get it out with a easy-out it is in there tight & I beleive I messed the thread's up when trying to remove it once already with the same punch (bad idea) oop's darn what to do ? thanks everyone.

05-09-2007, 5:00 AM	#11
MuayThaiFan Join Date: Apr 27 2007 Location: Singapore Posts: 79	Re: I have stripped & now broke bolt's how to remove ? help. If you're not confident of the job, I'd seriously suggest riding the bird down to a competent mechanic and have him do it for you. Seriously, you could end up damaging your paint work or fairing, then it'll really get expensive.

05-09-2007, 7:21 AM	#12
rosanne Join Date: Oct 20 2006 Location: Australia Posts: 57	Re: I have stripped & now broke bolt's how to remove ? help. Don't know where the Allen bolts are but you could use a cutting disk to put a cut in the top of the bolt and use a blade screwdriver or impact blade to get it out __________________ Grab your ankles world I'm coming through

06-12-2007, 11:25 AM	#13
XXMAN Join Date: Nov 01 2006 Location: WEST JORDAN Posts: 60	Re: I have stripped & now broke bolt's how to remove ? help. BUY A SCREW EXTRACTOR SET FROM HARBOR FREIGHT OR SEARS.

06-12-2007, 1:47 PM	#14
fzrcbrklxrider Join Date: Apr 08 2007 Location: Texas Posts: 209	Re: I have stripped & now broke bolt's how to remove ? help. I was going to buy a left handed drill bit & screw extactor, but the screw&thread's were damaged beyond repair. I ended up drilling out the broke-off screw, & threaded the hole, aluminum is alot easier than steel IMO. __________________ When exotic dancer's compete you win !!!