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Radiator shroud bolt spins but wont undo.

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Cant get one of the shroud bolts that goes into the tank out. It seems the insert on the tank is spinning. Anyone have any good ideas on how to get the bolt out, without wrecking the shroud?

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SOME times you can put 3m weatherstripping glue around the insert and that will hold it enuff to crack the bolt loose via an air wrench, but if it is really seized, you may have to remove the insert too: spin the bolt with an air tool/drill while carefully prying out on the insert. Once it is out, epoxy it back in. This is also the method that Eric Gorr's excellent book recc's.

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Your going to end up pulling the insert out of the tank, so ya need to do it with the least amount of damage to the tank.

As you loosen the (or try to) Im sure there is a point where it feels looser than others, right? At that point is where you need to just grab the bolt with a pair of vice grips and pull the shroud, bolt and the insert off the bike (insert out of the tank). At that point you can get the insert off the bolt by just holding it with a pliers or whatever.

Then you can do a couple different things to put the insert back into the tank. The first thing Id do is clean up the threads in the insert with a tap. After the insert is all clear, clean it with brake cleaner or something (no residue). What Ive done in the past is this: Pull the tank out and find one of the mold seams. Scrape some of the plastic off the seam and put it into the inserts hole with the tank placed so the hole is straight up. Once youve got a bit of "replacement" shavings in there, heat the insert up with a propane torch ( heat gun would work too) it only has to be hot enough to melt the plastic a little, not liquifiy it or anything. While hot push into the hole in the tank. NOT TOO FAR! Just till it sits like the others in the tank. Let it cool. Ya should be done.

Ive also used JB weld on the insert too, that works as well. But you have to wait to let it cure all the way.

Does that all make sense?

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