Hi,

I've been experiencing a very stupid, frustrating and nerve-wrecking issue. Every time I try to add/remove/mod my xt660z (2010, bought new from a Yam dealer) I am stopped by an allen bolt or more!
The first time was when I replaced my brake pedal the bolt was already messed up for some reason?! and I had my local bike alley shop to hammer a torque 30 in, so that I could unscrew the bloody thing.

Now, I took a day off to fit a PCV and MTC can, and again same problem... Two messed up allen bolts on the side crash panel, so can't remove the tank! And one under the pipes that turns ad vitam eternam.... but doesn't unscrew...

So... went back to the helpful local shop begging for assistance, but the guy wasn't there so now I feel a bit screwed I will not be able to get another day off before some time so I will have to pay for labour hours to get it done.
I am sure you can imagine my frustration!!!

I am definitely mechanically challenged, and I own only household tools (wrenches,allen keys, screw drivers etc...) but come on the task doesn't seem that difficult!!!

Anyways had anyone had similar problems, could it be a manufacturing issue? Should I ring my Yamaha dealer and get him to do something about the bolts?

Cheers,
P.

Ok tihs is only a suggestion, try to warm up the bike up a bit so that the bolts are warmer, go for a ride then soak bolts by spraying WD40 all over them, so that it penetrates in the grooves, go for a ride again get it nice and hot and then try again to undo them. The reason I am suggesting this is because I have seen a mechanic once, warming up stiff bolts with a blow torch a quite close distance however never near a fuel tank, usually exhausts bolts because they get really gritty by all the crap that a wet road throws on to them and because some idiot uses loctite on bolts!

It might work!

Thanks Captmoto I will try that after a ride then!

yer can't beat the old impact driver in a lot of cases..
Allen screws ..if you can get them in., a pair of vice grips if the hex is shagged

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The easyest way to turn gasoline into noise with out the side efect of horse power...

Often, tightening a bolt a tad will help to break the bond, and goes against the pressure points of the bolt/screw so making removal easier.

There are some very good ease and release oils out there - a trip to Halfrauds might be in order! IF you can get the oil onto the threads....

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Never underestimate the power of stupid people in large groups.

In addition to the above excellent advice (heat, penetrating spray, tighten then loosen etc) I really can't stress strongly enough how much more smoothly things will go if you invest in a "good" quality hex drive socket set. I know it won't necessarily help with the ones that are fooked already, but a snug fitting tool (cue GULG retort ) will prevent any more occurrences and give a lot more purchase on seized fittings.

You're bike sounds like maybe the previous owner has tried to remove seized bolts with the sort of use once "shiny Chinese - made of cheese" (rounded off probably) allen keys left over from flat pack furniture kits - I've seen it (and suffered the consequences of it) so many times.

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Thanks for your answers, good tips!!!

However in my case the hex on the bolts I mentioned have been completly f@@@ed, not by me btw, since I never touched them before realising this. The one on the crash panel is I think impossible to get a grab on with a vice, because it is screwed in a holow spot in the panel... I will still give it a go though... As well as the sprays...

Been doing some research at work and saw that in similar cases the bolt needed to be drilled... ?

Anyways will try everything you guys said, if it doesn't work will still be helpful for the future!

That's the thing I bought it new?!?! That's why I get so frustrated! I will defo get some proper good tool as soon as I get paid!

Didn't notice that!

Begs the question - what's the dealer like???

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If they are completely Fooked, try cutting a groove into it with a sharp chisel and knocking it around

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