So I bought a MM 2 in to 1 exhaust. Tried fitting at the weekend. it was all going well until I tried to remove the two allen bolts on the guard for the O2 sensor. I've completely stripped the allen bolts. I've applied penetrating oil and left for several days, I've applied heat, I've cut a line down the centre of the bolts so I can use a flat head screwdriver, I've even tried swearing at it (extensively).

I've got to the point now that I'm thinking about just sawing the heads of the bolts off and removing the guard using a bit of brute force. My thinking is that once I have the guard off I can just purchase some new bolts to attach to my new MM system. To be honest I may have to replace the bolts anyway considering the mess I have made of them.


So my questions are...

Am I barking up the wrong tree with my plan of sawing the heads off the bolts?

Does anyone know what size and type of screw I should be using to replace the old?


(Disclaimer: I am a complete novice and I may need things spelling out)


Thanks in advance!

No, I reckon I'd be barking up the very same tree!

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Ah, did you try wacking them? Mine were tough but a good wack on the head (them not me) with a hammer helped. You'll need to get them off anyhow (or the old system is un-usable) so cutting = last resort.

Heating them is another method.

Swearing should accompany all methods, iv'e been reminded of this today with my first try at a motard tyre change- Argh

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XTX 09

Hi Arn

Blimey you kids can't be trusted to do anything!!!! that's the bad news!!!

The good

Just grind or file the heads off(don't mark the cover!!) and drill what's left out at your leisure.

What you want is M6x12

http://www.ebay.co.uk/itm/M6-A2-Stai...item19ed35e663

Or ping me you address and I'll send you my originals I found some stainless but put them in mine and took the others out sorry mate!!!

I've tried giving them a good whack and another heating as advised but still no luck so looks like I'll be removing the bolt heads by force.

Thanks for the words of reassurance gents! I'm always very nervous of doing something irreversible.

Waynovetten,

You're a star! Cheers for the offer but I might treat my self to some snazzy new stainless steel bolts now that I have the right size.

In my defence, I fitted the handguards with almost no issues... almost.

I always thought stud exstracters were a bit of a gimmick til' I added some to my tool box. They come in various sizes & have a left hand thread so as you 'screw' them into the hole drilled into a snapped or stripped bolt it then winds the said bolt out of its right hand thread, if you catch my drift?
But get the dearest ones you can afford as the cheap ones also snap easily.
Good luck.

I'd go along with sweller on the anti-clockwise drill bits, but if you round off a socket head (Allen) you can belt in a torx bit with hammer and that may work. Use a decent quality bit or it will probably just snap though. The hammering of the bit into rounded off Allen socket helps free the stuck thread. Another method I've had success with in the past is to tap a welding rod onto the bolt so it gets stuck, that heats the bolt up nearly red hot and then turn off welder leaving rod stuck to bolt and bend rod over,wind out bolt. Good luck!

I've ordered some left handed drill bits and will be giving that a try this weekend. It's probably for the best. The closest thing I've got to welder is the missus' hair dryer!

Let�s not lose sight of the principle objective here, which is I guess, to get the O2 sensor out as quickly, easily and cheaply as possible?

While you�re sitting around waiting for your LH drill bits to arrive, why not just cut/grind/file/drill (delete as appropriate) off the heads of the offending bolts, remove the cover and unscrew the sensor. Refit the sensor to your Metal Mule header and off you go!

You can then tackle the stuck remnants of the bolts at your leisure while still being able to ride your bike.

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Good point well made but you haven't taken into account one vital factor. My complete unparalleled ability to mess up the simplest of tasks! I've made a pig's ear of one of the exhaust manifold bolts as well now so all work must grind to a halt until my new drill bits arrive.

I sort of accepted that doing the exhaust fitting myself would result in the bike being off the road for a few days/weeks/months/indefinitely. I've still got my Versys to keep me occupied while I stock my toolbox

Hopefully I won't need to turn up to the Wales meeting on it!