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jcolborn48

How to take out a stripped bolt?

10 posts in this topic

I stripped the allen bolt that holds the header on to my '07 450 :banghead:. How screwed am I? What do I do next? Any ideas appreciated.

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Get a chisel and hammer tap and notch in it and tap it loose. An air hammer works best but you can do it by hand. I just did the same thing yesterday....I HATE ALLEN BOLTS. You can also try some vise grips if you can get to it with them. My bike is a steel frame so I had room.

Another way is to take a 12 point socket (that you don't mind destroying) that will fit over bolt head by smacking it on with a hammer.

Bolt may also snap off in head which is no big deal if there is enough room you can just put a nut on it

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I stripped the allen bolt that holds the header on to my '07 450 :banghead:. How screwed am I? What do I do next? Any ideas appreciated.
Do you mean you stripped the threads out of the head, or the hex socket out of the Allen bolt itself?

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Do you mean you stripped the threads out of the head, or the hex socket out of the Allen bolt itself?

The hex socket out of the allen bolt

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That should be fairly simple. Loosen the hex nut on the stud first to take the tension off the Allen bolt. Then, you can probably just unscrew it. If it's really trashed, you can try jamming a Torx bit into it, or a big screw extractor.

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Take a dremel tool with a cutting disc and slice a screw driver notch in it, then un-screw it.

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Take a dremel tool with a cutting disc and slice a screw driver notch in it, then un-screw it.
You do know where this particular Allen head is, don't you?

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Yeah, dremel would be tough to get in there. But I was able to get it with a wedged in torx head, Thnx Gray

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Cool. Because Allens have that tendency, I always leave the nut and stud a little loose, tighten up the Allen to about 3/4 of its required torque, then crank the nut down. That causes the flange plate to tilt a bit, "tightening" the Allen farther without actually turning it.

When ever I loosen the flange, I always loosen the nut first.

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