another bolt focc-up ideas?

[Val]

Hello,

I have tried to add new rad cover. 3 bolts have untighten fine. The 4th one - another bolt foccup.

First the hex key has twisted like spaggeti  , the second 4mm hex key bit I just bought from Halfords has drilled the bolt 

See pictures. Any ideas how I can fix that? I have applied industrial amounts of WD40 and penetration fluid before the final attempt to no avail.

Do I need to go to the nearest machinist shop for help?? Is there any easy way to unscrew that bolt?

Note the bolt goes into the side of the radiator which looks to me some sort of hard aluminium alloy, the bolt is steel. It is tighten so hard looks like melded.

EDIT: just reading some horror stories aparently steel bolts can be fused with the aluminium through galvanic action. Seriously guys? 

[darrsi]

That's the same reason the rear disc bolts can be a total bastard to remove.

[Val]

That's the same reason the rear disc bolts can be a total bastard to remove.

Thank you Darrsi I think it's time to sell the new rad cover and just leave the radiator in peace  I mean in one piece 

[Paulfzs]

mine came off pretty easily and i had no issues with them.

[joebloggs]

Cut a slot and gently tap it round or carefully drill it out

[darrsi]

mine came off pretty easily and i had no issues with them.

Fell off you mean? 

[anutz]

3 of mine were actually loose!


I had issues with some bolts on the inside of the Magneto Cover last week, used a Left handed drill bit, really small to drill a pilot hole and then a extractor wound into the drill......came out fine...


Could you just use a left hand drill bit to drill it out?

[Doggy]

I am awaiting delivery of a rad cover (coming Thursday) so just been in the garage and all four came out no problem.

Have you tried using a chisel on the edge of the head and tapping it around, it can help free it off and worked on one of the screws in my throttle assembly that was doing the same thing to me!

Good luck hope it comes free for you.

Doggy

[Val]

I am awaiting delivery of a rad cover (coming Thursday) so just been in the garage and all four came out no problem.

Have you tried using a chisel on the edge of the head and tapping it around, it can help free it off and worked on one of the screws in my throttle assembly that was doing the same thing to me!

Good luck hope it comes free for you.

Doggy

thank you, need to go buy a chisel. Somebody told me to try to fit torx there will try that first, than will go the extractor route.

I have removed the other bolt so hope tomorrow going to work the potholes to loose it a little bit 

First time I will be glad to loose some parts during ride 

[Val]

I have tried Torx harmless approach as proposed by a guy on some other forum and it worked thank you Lutin for your help 

Bought for £4.61 set of good hard steel Torx bit sets yesterday.

They have arrived today. I have embedded T27 which is 5mm but has managed to tap it in 4mm hole with the hammer. I was a little pissed off so may have not been so gently as advised.

Anyhow after soaking with penetration fluid and waiting for 2 hours for my radiator to cool off after the ride, I have tried using about 1 foot long arm doing most of the pressure pressing with my right hand towards the bolt and actually untightening very little with my left hand. It bulged half a mm. I have tighten it back. Than untighten again a little. You got the mood.

It worked ;D

I have new ugly radiator cover mounted! Ugly because the fit was not ideal and it bend. Frankly I do not care 


 

[7omly]

With regards to the bend, this happened when I fitted a replacement. I took it off and put a couple of washers on the inside of the mounting points, (bloody tricky) but it took the bend out.

[joebloggs]

With regards to the bend, this happened when I fitted a replacement. I took it off and put a couple of washers on the inside of the mounting points, (bloody tricky) but it took the bend out.

If you want to do this mark the position of the screw head on the out side of the cover, remove it, araldite the required amount of washers together, put a nut on the back of the screw, araldite the washers to the back of the panel, leave to set.

Simples.......

[fazersharp]

Under your new one it looks like there is already a mesh or is that part of the new one.

I got this one off ebay and fully expected to have a faf fitting it as everyone seems to, it like different year rads are different sizes but all covers are one size.
Any who it was a perfect fit, I dont much care for the ones that say fazer as I think it looks a bit teenage boy racer 

But on the other hand ----- BBQ anyone !
 

[mobile mouse]

Fazersharp can you post the link to the ebay part, please.
Looks good.. It your bike a foxeye or boxeye.

[fazersharp]

Its a boxeye
But it was just a private seller who was selling parts and so I don't know where you would get a new one