UNREMOVABLE BOLT

Hi guys:

After a full cylinder gasket change, engine and body re-painting, carb cleaning, new plugs, new brake pads, new oil and fuel filters and other minor things, my baby is almost ready to roll again...

But there´s still a little thing that keeps me from finishing my job: There´s a little oil leak in the oil cooler lines right where they meet with the oil pan, so I decided to change o-rings and put new bolts on, but there´s one that won´t go out and worst of all it has gone "rounded".

What do you suggest me to do? File one side of it so I can work it with a smaller wrench, or make a slot on it with a steel saw, so to try to take it out with a screwdriver?

Sorry for my english, any answers will be welcomed!

BTW, the bike is my ´84 Gpz550, not the one showed in the avatar...

wow thats a nice looking bike! i dont think the screwdriver trick will work on that big of a bolt.since its already chewed up id say clamp a pair of vise-grips on there and see what happens.

if that doesnt work, use a flat file to either make it fit the next size smaller socket, or make it flat like a wing nut so vise grips can get a really good hold.

VERY nice bike! Love the '84 transitional style.

I have a similar problem with the tiny screws holding the Kawasaki logo onto the gas tank. Tiny tiny screw, completely rounded out, no edges to grab on, rusted solid. Dunno what to do with this either!!!

Drill out the head of the screw with a bit the size of the threads. Take the logo off, then apply WD-40 or Liquid Wrench, let it sit for a while, then remove it with vicegrips.

mind2find wrote:

VERY nice bike! Love the '84 transitional style.

I have a similar problem with the tiny screws holding the Kawasaki logo onto the gas tank. Tiny tiny screw, completely rounded out, no edges to grab on, rusted solid. Dunno what to do with this either!!!

Thanx guys!

I´ll try the file trick, if it doesn´t work will go borrow the vise-grips from a friend...:blink:

Wish me luck, I´ll post some pics when I get her our of the garage.

I would use a hand impact driver on that bolt head. The hand impact drivers have a 1/2" drive. Fit a 6mm 1/2" drive socket on and twist the impact driver counter-clockwise and give it a sharp rap with a hammer. It will likely loosen. If that doesn't work and you feel like you are going to snap the head off, I would consider vise-grips and then drill the bolt, if the head broke and install a new bolt after tapping new thread. In the event you mess up the hole when drilling, you can install a 7mm x 1.0 pitch bolt of similar length.

Heat the bolt head with a pencil tip torch until the head starts to turn red. Let it cool a little and turn it out with the pliers. Thats if you have a torch or access.

I'm with George on this one. I have a 3/8" drive hand impact wrench that I've used on a lot of the "single use" fasteners that came on our engines. I always try to replace everything with stainless steel if I can...



Post edited by: guitargeek, at: 2006/08/29 00:11

If the tool of last resort, aka Vice grips, dont work then try these:

cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&i...1542733&category=303

Just be careful and dont snap them off in the bolt, it woll make it infinately more difficult to drill out. Or so I hear. :whistle: :whistle:

cut a slot into the bolt, heat the area around it with a propane torch, use an impact driver and give it a very sharp rap with a hammer using ALOT of hand generated twist toward the direction of counter clock wise. Give that sucker a very hard rap with a HEAVY hammer while holding the impact with a counter clock twist like you've never before, and if you dont git it out ill send you my adress so you can come over and explain what went wrong. put a pipe behind the piece, supported by something solid so you dont break that corner off the motor.

Post edited by: nads.com, at: 2006/08/29 03:14