problem with a scratched fairing bolt - how do I remove?

[doktor]

OK, so I'm riding my bike before Xmas, about 5 mins from home, cold tyres, cold road, coming off a roundabout car infront pulls up quite quickly for a pedestrian crossing. I was a bit close, grab the breaks, front wheel goes and a low-side (left side). Didn't hit the car, was only doing 15 mph or so, just scratches and a bruised ego, no problems.

Annoyingly, I had crash bungs sitting at home, arrived 2 days before and not had time to fit them! Now, from the spill, i cant remove the left hand fairing bold (old style 'Busa, 05). The scratch has damaged the allen key hole. It's not totally gone, but the shape is out (will try get a picture).

My question is, how can I get this bolt out? I've tried a screwdriver and smaller allen key, but it won't turn and looks like it'll just burr the bolt. It might have actually bent the bolt a bit, making it harder to turn. So what can I do? How do I get it out? I'd like to do it at home if possible, to learn, but if a garage is the answer, let me know!

ps. the bike in the picture isn't mine, it's just to show which bolt I mean.

[ibified]

if it were me, Id probably get a dremel tool with a metal cutting blade and cut a notch across the face of the bolt, then see if i could turn it out with a flathead screwdriver.

I've done this with stripped bolts in the past with a fair amount of success.

[UncleSteve]

are you good with a drill? drill the head off it.... or
if not you can try to wrap some tape (small amount) around the allen wrench, then tap in into the bolt, tap on it as you turn it.
you could try JB weld or another epoxy on the wrench, leave it over night and try to turn it the next day.
if you have a small dremel, try to notch it so a flat blade screw driver will fit.

If it is really tight, drilling the head off the bolt might be best, but a little risky if you drill too deep and ruin the threads, then you open up another problem, heli coil time.

[gurrera]

If you tap on the allen head bolt with a flat punch or drift so too flatten the allen hole and make it smaller.

Then you can drive a allen wrench socked in to it and that might help.

If not you will have to get read of the head of the bolt like UncleSteve suggests.

Good luck

[rubber2burn]

Just give it a couple of raps with a hammer and it should loosen up. When you replace it I recommend not tightening it so much those bolts only need to tightened just a little and they will hold just fine.

[black07busa]

Sounds like the allen whole is rounded off a little. I've used torx bits in the past to help remove a allen head screw, they tend to be the right size for rounded off allens. But it will take some extra elbow grease if the bolt is bent. Good luck.

[mike1180]

if it were me, Id probably get a dremel tool with a metal cutting blade and cut a notch across the face of the bolt, then see if i could turn it out with a flathead screwdriver.

I've done this with stripped bolts in the past with a fair amount of success.

Done this also myself.
Works great.

[Mr Bogus]

good ole "Blue nosed wrench" works every time...

[mike1180]

good ole "Blue nosed wrench" works every time...

Ha!
Wish I had a dollar for everytime I got PO'ed and yelled "Get the torches"

[ibified]

That'd work well, except for the fact that said bolt is surrounded by a plastic fairing.

[sixpack577]

The tapping with a hammer, and the torx bits are great suggestions, one or both should work. If not, the next thing I would try would be these removal bits from Craftsman. They're cheap and work very well. If you use them in a drill, start slow.

[sixpack577]

sorry, here they are.

[Strife]

EASY OUT BIT!

Basically you drill into the head of the bolt. Insert the easy out bit. Turn the bit by hand or drill in the direction you would normally to unscrew it. Buy a new bolt. Don't over tighten the bolt when you tighten it back up. Or you will end up with the same issue of the allen head hole stripping.

Can buy an whole easy out bit set at harbor freight for under $10. comes with the bits and drill bits and instructions.

- Harbor Freight Tools - Quality Tools at the Lowest Prices

Can buy a whole kit here(or just one bolt) and get them colored if desire...

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