Another stripped bolt thread

[superduc21]

Went to do a brake job on my 99 Supersport, (first one since I had the bike) and 1 of 2 bolts that hold the caliper on stripped. I tried the grease and sand, torx, screwdriver, and vice grip tricks. Nothing seems to work. It looks like this thing is so tight that an easy out would probably break off. Any ideas or should I just give a mechanic shop my wallet so they can do it?

[Hyperpasta]

I’d try and soak the bolt with some PB Blaster for a couple of days then drill out the bolt for an Easyout!

It should come out without a hitch.

[Nick D.]

Normally the binding of the bolt occurs between the head of the bolt and surface of whatever you are working on. If you aren't able to get it out the easy ways, try a big drill and drilling the allen head to the point where the head comes off onto the drill. At this point an easy-out will have a pilot hole and should be able to remove the threaded part of the bolt without issue. Don't ask me how I know...

[superduc21]

Thanks for your help! That will give me something to do tomorrow

[jpuck91]

Addition to NickD's post: As long as the threaded portion of the bolt isn't seized in the fork leg, once you've ground off the bolt head you should be able to remove the rest of the bolt without using an easy-out... Grind off the bolt head, once its off remove the caliper from the fork leg, then unscrew the rest of the old bolt from the fork leg. I've had to do that a couple times, both times the threaded portion could be unscrewed by hand.

[MAGNUMDUC]

Easy-outs work well if you have patience. Gooooo Slooooow with the drill, or you will snap the easy-out off in the bolt. Believe me it is not fun to drill out an easyout bit(they are very hard). If you have to destroy the head of the bolt, I found tungsten carbide bit in the dremel works great. Good luck, and please post how you got it out.

[NC Rick]

Originally Posted by MAGNUMDUC

Easy-outs work well if you have patience. Gooooo Slooooow with the drill, or you will snap the easy-out off in the bolt. Believe me it is not fun to drill out an easyout bit(they are very hard). If you have to destroy the head of the bolt, I found tungsten carbide bit in the dremel works great. Good luck, and please post how you got it out.

I would have to say that the eazy out won't work if the allen key didn't. You have to break down the thread lock or binding first. Heat of about 450 f will do it but you must put it to the bolt not the brake caliper where it could damage the rubber parts. Another trick is to tae a punch that fits into the allen socket and tap the fastener sharply. Drilling off the head is a potential solution. If you jam an EZ Out into the socket head, you won't be able to drill it!

[superduc21]

I had to heat it up, grind it down, cuss A LOT and 2 easy outs later..........

[JonHsiung]

Congrats! At least your problems are a lot better than mine. I've had two bolts that literally broke in half on the threading part while trying to take them out. Now time to pay someone to drill them out and provide new bolts.

[superduc21]

Have you tried removing them yourself? If you have a drill it is about $3 for a metal bit and $2 for an EZ out, I just use vice grips on the end of the EZ out to unscrew it. Thanks again to everybody who put in their input.

And screw the alan head, I switched to hex. looks funny but function before beauty!

[MAGNUMDUC]

Glad to hear you were successful. I think the cuss'n probably skeerd em out. I know thats what I had to use.

[jpuck91]

Originally Posted by superduc21

And screw the alan head, I switched to hex. looks funny but function before beauty!

The stock bolts are pretty crappy, once they're out it's a good excuse to replace them with stainless or titanium.