Help In Removing Stripped Brake Disc Cover Bolt

[Blue Hawaii]

The top one came out fine, but the bottom one is way stuck. Since using an Allen socket stripped the Allen hole, I've resorted to other means in just removing it. At this point, the factory bolt is wasted and will be replaced, so I really don't care about saving it.

I can't use heat to expand the metal since the plastic disc cover will melt. I've tried an impact wrench, impact phillps, dremel cut a slot for a screw driver, hammered a flat head screw driver into the Allen hole, all to no avail. I guess a bolt extractor is needed, but I really don't have time to go to Sears to buy one. Are there any quick and easy ways?

:banghead:HELP!!?

[motomanx]

get a torx bit that is just a tad bit larger than the stripped hole and hammer it in, then (if you have one) use an impact driver to remove it.

if you don't, just use a wrench (but the impact works great)

[Blue Hawaii]

motomanx:

Thanks for the advice, but that trick didn't work either. I've tried to use the methods stated above, plus a few new ones; heated the bolt with a pencil torch and cooled it off with cold water = didn't work. Sprayed the bolt with WD40, penatroil, PB Blaster "BreakFree" = didn't work. Rode it around the block a few times = didn't work, but felt good doing so! ?

Going to Sears now to buy a Craftsman EZ Out set (bolt extractor).

Riding the bike, of course!

Edited December 7, 2010 by Blue Hawaii

[FORMA MOTO]

Take warning that every other 'non-like metal' faster contact (brass inserts on tank, aluminum on swingarm adjusters, etc) will also corrode and get frozen. Remove all and use 'anti-sieze' compond from Honda.

[swissrallyman]

I would have drilled it out. Use a drill bit with a diameter slightly larger than the bolt, and drill into the bolt head. Once you are through the head and into the bolt shaft, the head will pop of and probably be stuck around your drill bit. Then remove the other bolts and remove the disc cover. Now you can grip the stuck bolt shaft with vice grips and turn it out. This will be easy because there is no more tension on the threads. Use anti seize or a little bit of grease next time.

[Old-Man]

Yes you will never get it out with just a screw driver. If you cut slot for a screw driver you need one of these. http://www.sears.com/shc/s/p_10153_12605_00947641000P?blockNo=4&blockType=G4&prdNo=4&i_cntr=1291689134942

Then like the other guys said. ALWAYS use some anti seize.

[Blue Hawaii]

swissrallyman: Normally, I would have just drilled it out and then used a pair of vice grips or something of the like to remove the stud, but this particular bolt is a flat head Allen with a collar.

Krannie: I know... I know... ?

Old-Man: I have that tool, and it just made matters worse. I have the proper Allen wrench tip and everything. I will try to use the EZ Out extractor I bought at Sears.

Side story:

Since I couldn't remove the front tire to change it from knobby to dual sport, I thought that I'd tackle the rear tire. I couldn't even bust the rear 32mm nut loose from the axle. I'm afraid to use a cheater bar on the socket wrench after how my morning went. Better break out the air compressor and pneumatic impact tools... Sheesh!

[SteveP1001]

That bolt sounds very stuck. I think i would just drill it out. If you go the EZ Out route be careful. The last thing you want is to break the thing off. I know this from experience. ? Those things are not as strong as they look, but they are very hard. Almost impossible to drill through.

In my case, I managed with a high dollar drill bit that a machinist sent me, but these places exist for a reason. http://www.brokentap.com/easy-outs.html

[crfxer]

I would have drilled it out. Use a drill bit with a diameter slightly larger than the bolt, and drill into the bolt head. Once you are through the head and into the bolt shaft, the head will pop of and probably be stuck around your drill bit. Then remove the other bolts and remove the disc cover. Now you can grip the stuck bolt shaft with vice grips and turn it out. This will be easy because there is no more tension on the threads. Use anti seize or a little bit of grease next time.

Thats just about perfect and exactly like it would go....but I'd use a 7/16" bit and just drill off the head of the bolt. Its got a collar on it and if you drill through the head and collar all the way to the stud you won't have anything to grasp with the vise grips

[supergper]

I'd just heat it and deal with buying a new disc brake cover.

[cubera]

Reverse drill bit?

[hazard88]

EZ Out bits after spratying some metal penetrating oil. I used Kroil if I'm remember my garage cabinets correctly. Loosens frozen metal parts up really well.

[Chairborne]

Depending on where in Hawaii you are, I'll give you a replacement screw and disk cover if you need one. I converted my X to supermoto and the cover isn't much good on a 320mm rotor.