Seized bolts

[DSH]

Hey fellas, looking for some suggestions on how to remove seized bolts. I'm currently parting out a 2001 R6 and have run into some problems w/ 2 bolts that connect the frame to the engine block.

The two problem children require Hex bolts to remove them and i've noticed that there's a good amt of wear on the bolt heads and the allen key is slipping a bit as I apply pressure. Before I cause any damage to the bolt heads, bc they are bolted into the engine and hope to sell it, I wanted to see about suggestions from you guys.

Thanks

[IrocRob]

A few things you can try:

Apply some penetrating oil, liquid wrench, wd-40, or whatever and let it sit overnight.

An impact wrench, if you have one available.

If you dont have an impact wrench, improvise.
Get an extension on the allen wrench, and hit it with a hammer.
Don't be a gorilla with it, you just want to break any corrosion free.

If it still doesn't move, try using a hand held torch on the metal around
the bolt, you want to warm up the case but not the bolt itself.

If you haven't moved it yet, chances are you've rounded out the hexagon
and you'll have to drill it out.

If the bolt hole runs "through" and you can see where the bolt would come
out on the other end, a regular drill bit will work fine.
If it is a "blind" hole, or if you are unsure which is which, get yourself
some left-handed drill bits. These are drill bits which are run in reverse.
With a little good luck when the drill bit "catches" it will spin the bolt out.

With a little bad luck the drill bit will break.

If you start drilling through the bolt, be extremely careful for proper alignment.
You really don't want to drill into the threads.

Take a close look at the way the engine will come out of the frame,
you may be able to use a drill bit that will take the head off of the bolt
and that will allow you enough movement to remove the engine.

Or maybe enough room to get a hacksaw blade in there and cut the bolt itself.
Then you can work on the engine out of the bike, much easier that way.

If it's still in there after all these attempts, then it's time to start looking
for a beer, and call someone else to take care of it.

Good Luck

[carl_g]

you can also score across the head of the bolt with a dremmel. Be careful
Make a notch so you can fit a regular screw driver in there.. The like rob said penetrating oil and or heat along with a impact driver.

I would try this before drilling it.. It is really hard to drill through a bolt in my experience.

[DSH]

A few things you can try:

Apply some penetrating oil, liquid wrench, wd-40, or whatever and let it sit overnight.

An impact wrench, if you have one available.

If you dont have an impact wrench, improvise.
Get an extension on the allen wrench, and hit it with a hammer.
Don't be a gorilla with it, you just want to break any corrosion free.

If it still doesn't move, try using a hand held torch on the metal around
the bolt, you want to warm up the case but not the bolt itself.

If you haven't moved it yet, chances are you've rounded out the hexagon
and you'll have to drill it out.

If the bolt hole runs "through" and you can see where the bolt would come
out on the other end, a regular drill bit will work fine.
If it is a "blind" hole, or if you are unsure which is which, get yourself
some left-handed drill bits. These are drill bits which are run in reverse.
With a little good luck when the drill bit "catches" it will spin the bolt out.

With a little bad luck the drill bit will break.

If you start drilling through the bolt, be extremely careful for proper alignment.
You really don't want to drill into the threads.

Take a close look at the way the engine will come out of the frame,
you may be able to use a drill bit that will take the head off of the bolt
and that will allow you enough movement to remove the engine.

Or maybe enough room to get a hacksaw blade in there and cut the bolt itself.
Then you can work on the engine out of the bike, much easier that way.

If it's still in there after all these attempts, then it's time to start looking
for a beer, and call someone else to take care of it.

Good Luck

Thanks for the suggestions. Appreciate the tip re: heating the casing and not the bolt itself. I was a bit concerned w/ inadvertantly heating anything inside the casing, ie rubber seals, etc. I'll try my best and let you know. thanks again.

[RCM78]

Make sure your using a quality allen key that fits tight in the bolt head. Tap it in with a hammer. Once it's seated give it a few good hits. An impact driver should work if you dont have an impact gun. They're cheap at sears too.

[FigNewTon]

These worked great for me removing the stripped engine mount bolts on my Kawi. The heads on those damn things seemed to made of silly putty and even after tapping in a smaller allen key they still stripped.

http://www.sears.com/shc/s/p_10153_12605_00952166000P?vName=Tools&cName=HandTools,GeneralPurpose&sName=Bolt-Out,%20Taps%20&%20Dies&psid=FROOGLE01&sid=IDx20070921x00003a