Front Tank Bolt with stripped head

[FJRScrewball]

I wanted to do the throttle return spring mod before coming to EOM and as I started to remove the 2 front tank bolts I realized the dealer who did the ECU replacement stripped out the allen head on one of the bolts. Thought about drilling and using bolt extractor but wanted to hear any other ideas first. Anyone?

 

[CAJW]

I wanted to do the throttle return spring mod before coming to EOM and as I started to remove the 2 front tank bolts I realized the dealer who did the ECU replacement stripped out the allen head on one of the bolts. Thought about drilling and using bolt extractor but wanted to hear any other ideas first. Anyone?

Personally I'd take it back to the dealer and say "fix it!". I'd also be there to supervise that they don't screw anything else up. If they deny they caused it then you can post your bad experience on this forum and print them a copy for their bulletin board.

 

[Silent]

You can use a slightly larger allen head socket. I believe one of the SAE ones will work. You put it on an extension and drive it into the head with light taps from a hammer. That will give you the purchase to remove the f'ed up screws. Then install new screws with the knowledge that they do NOT have to be that tight. Hell there only holding the tank down and are under no real stress.

Don't ask me how I know this BTW. :huh:

 

[FJRScrewball]

You can use a slightly larger allen head socket. I believe one of the SAE ones will work. You put it on an extension and drive it into the head with light taps from a hammer. That will give you the purchase to remove the f'ed up screws. Then install new screws with the knowledge that they do NOT have to be that tight. Hell there only holding the tank down and are under no real stress.
Don't ask me how I know this BTW. :huh:

Yep, tried that already, no luck, but thanks for the reply.

 

[FJRBluesman]

Better option:

Gunny getting the dealer to fix it.

OK Option:

If you can't get the next size up hex bit to fit after pounding it in with a hammer, try to cut (very, extremely, carefully) a slot in the head with a die grinder, or some other tool.

 

[Badcat]

My ***** dealer over tightened the tank bolts causing the heads to strip the next time they were removed. I ended up drilling the rest of the head off, removed the tank, then I was able to unscrew what was left and replace the bolts.

 

[FJRScrewball]

I wanted to do the throttle return spring mod before coming to EOM and as I started to remove the 2 front tank bolts I realized the dealer who did the ECU replacement stripped out the allen head on one of the bolts. Thought about drilling and using bolt extractor but wanted to hear any other ideas first. Anyone?

Personally I'd take it back to the dealer and say "fix it!". I'd also be there to supervise that they don't screw anything else up. If they deny they caused it then you can post your bad experience on this forum and print them a copy for their bulletin board.

Thought about that. Since they were the last to have the bolt out let them fix it. I'll see what they say when I get back from EOM.

 

[pmspaul]

You can use a slightly larger allen head socket. I believe one of the SAE ones will work. You put it on an extension and drive it into the head with light taps from a hammer. That will give you the purchase to remove the f'ed up screws. Then install new screws with the knowledge that they do NOT have to be that tight. Hell there only holding the tank down and are under no real stress.
Don't ask me how I know this BTW. :huh:

Yep, tried that already, no luck, but thanks for the reply.

If you have torx bits, try the method above with a torx that needs tapped in with a hammer.

 

[madmike2]

When you DO get them out, you might consider replacing them with hex bolts like the older generations have.

 

[johnny80s]

Once you get them out use a regular bolt and not a allen for replacements.

 

[RadioHowie]

OR if you like allen bolts, replace with stainless steel instead of the potmetal cheez whiz brand Yamaha uses.

 

[ShinyPartsUp]

OR if you like allen bolts, replace with stainless steel instead of the potmetal cheez whiz brand Yamaha uses.

Still pissed off about that tenth head bolt breaking your fine Stanley cheez whiz 12mm socket Howie?