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Removing shrouds from tank - Bolts stripped

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Can anyone help me. The bolts that hold the shrouds to the tank on my YZ450 '05 is stripped and can't come loose. Think this is a common problem on these bikes. How do i go about? Want to fit new shrouds.

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Those phillips head screws are really soft aren't they?Since they're junk use a small very sharp chisel and try to turn it just a hair,sometimes once you free the little devil it'll turn with the screwdriver.If that doesn't work try grinding a slot with a cut-off wheel [small] to fit a standard screw driver.I hate easy outs and such but that would be a last resort.

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Your approach to this will depend a little on which bolt(s) is stuck, and to some extent, why. The ones in the recessed holes are more difficult to access. Then, too, if you are willing to butcher the shroud to get it off (depends on why you're replacing them), you can open up your options a little.

If the bolts were replaced by some that are too long, they may be jammed at the bottom of the threads, which will cause a separate set of problems.

But otherwise, one of the simplest ways to fix this is with a drill:

> Drill a 3/32" hole a short way down into the screw head. Phillips screws are easy to get centered on.

> Then, use a very sharp, left hand twist drill, and try to make the drill "stick" in the pilot hole you made. With luck, the drill will catch, and spin the screw out.

Other methods involve drilling the head off, and then unscrewing the stub with pliers, or with an "EZ-out", or drilling the washer under the bolt in a few places so that you can break it out from under the screw, loosening the tension on it. If you have access, or cut the shroud away, you can use the point of a small chisel at an angle to turn the screw.

Also, if it's only one that won't come out, you can remove all the others, and then, while applying what torque you can to the screw, rotate the entire shroud around the screw to snap it loose.

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Your approach to this will depend a little on which bolt(s) is stuck, and to some extent, why. The ones in the recessed holes are more difficult to access. Then, too, if you are willing to butcher the shroud to get it off (depends on why you're replacing them), you can open up your options a little.

If the bolts were replaced by some that are too long, they may be jammed at the bottom of the threads, which will cause a separate set of problems.

But otherwise, one of the simplest ways to fix this is with a drill:

> Drill a 3/32" hole a short way down into the screw head. Phillips screws are easy to get centered on.

> Then, use a very sharp, left hand twist drill, and try to make the drill "stick" in the pilot hole you made. With luck, the drill will catch, and spin the screw out.

Other methods involve drilling the head off, and then unscrewing the stub with pliers, or with an "EZ-out", or drilling the washer under the bolt in a few places so that you can break it out from under the screw, loosening the tension on it. If you have access, or cut the shroud away, you can use the point of a small chisel at an angle to turn the screw.

Also, if it's only one that won't come out, you can remove all the others, and then, while applying what torque you can to the screw, rotate the entire shroud around the screw to snap it loose.

Gray, i have seen many, many of the YZ's with this problem. It's always one of the rear shroud bolts too. I have seen the bolts so "stuck", that alot of PB blaster and an air gun won't break them loose. They can be removed though, sometimes you can even save the shroud but the shroud has to come off so you can get to where you need to work. Those brass inserts are very long. They are probably an inch long. I have been able to lightly trim away enough of the plastic on the side of the insert and grab ahold of it with some Snap-on Duckbill pliers. Then just blast the bolt out with the airgun. Whatever you do, don't pull the whole bolt and insert out of the tank!!!!!!! You will NEVER get it back in.

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Whatever you do, don't pull the whole bolt and insert out of the tank!!!!!!! You will NEVER get it back in.
It's actually not so hard to do, but that technique should definitely be a last resort.

Yet another method to try if you are both skilled and lucky is to us a .060-.080" drill to drill at an angle through the plastic adjacent to the insert and into the insert itself, stopping before you intersect the threads. Then flip the drill bit over and push it back in, using it as a pin to hold the insert while you try again to free the bolt.

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It's actually not so hard to do, but that technique should definitely be a last resort.

Yet another method to try if you are both skilled and lucky is to us a .060-.080" drill to drill at an angle through the plastic adjacent to the insert and into the insert itself, stopping before you intersect the threads. Then flip the drill bit over and push it back in, using it as a pin to hold the insert while you try again to free the bolt.

I had a guy bring me a tank that he pulled both inserts out of both sides at the rear mouting points. They will go back in.................. i'm not a big fan of using epoxy to Glue um back in.

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I had a guy bring me a tank that he pulled both inserts out of both sides at the rear mouting points. They will go back in.................. i'm not a big fan of using epoxy to Glue um back in.
It really isn't an ideal solution, is it? Sometimes, though, it's that or a new tank.

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It really isn't an ideal solution, is it? Sometimes, though, it's that or a new tank.

Yes sir. I prefer things that are PROPER though. Sometimes ya gotta do what ya gotta do. Not on my machine though.

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