I've had my GS for about 4 months now and im doing a bit of a clean-up, but since this is the first time i've really dismembered the bowels of the bike im coming across a few bolts that may not have been undone for quite some time (the bike is 7 years old now).

One of the bolts securing the exhaust to the cylinder head (the other three came out all right, but were still a bit rusty)

Three of the screws securing holding the bottom of the carbs (to get at the jets) in place (i got one free but the others aint budging). I'm a bit worried about these ones because each attempt mashes up the screw head a little bit more.

I've given them all a good dose of WD-40 to see if that helps but does anyone else have any good ideas?

Use a pair of vise grips on the head, or use a Dremel to cut a slot in the top of the screw.   

Quote from: crazyfish on April 12, 2008, 05:40:37 PM
I've had my GS for about 4 months now and im doing a bit of a clean-up, but since this is the first time i've really dismembered the bowels of the bike im coming across a few bolts that may not have been undone for quite some time (the bike is 7 years old now).

One of the bolts securing the exhaust to the cylinder head (the other three came out all right, but were still a bit rusty)

Three of the screws securing holding the bottom of the carbs (to get at the jets) in place (i got one free but the others aint budging). I'm a bit worried about these ones because each attempt mashes up the screw head a little bit more.

I've given them all a good dose of WD-40 to see if that helps but does anyone else have any good ideas?

EDITED:

I missed the part about the carbs on the first read. Vicegrips is the way for the float bowls. Forget what I said earlier about tapping on the heads of the screws. That was intended for the exhaust bolts, which you've already gotten out.

i'm an idiot

The screws on the float bowls are awful, I had the same problem.  Vice grips got 'em off for me.  Go to the hardware store and buy some replacements, I like allen head's for that application.   

Wait till you try to take out the brake rotor bolts! I broke a craftsman allen socket trying to break those loose, stripped a head and had to drill it out. When I finally got them all out there was tons of dried up threadlock, it was the red stuff which I think is the strongest?

Quote from: bucks1605 on April 13, 2008, 07:13:51 AM
Wait till you try to take out the brake rotor bolts! I broke a craftsman allen socket trying to break those loose, stripped a head and had to drill it out. When I finally got them all out there was tons of dried up threadlock, it was the red stuff which I think is the strongest?

mmm, red is for like, stuff you never ever want to take out. ever.

blue is for keeping things safely snug.

iirc there is a green now, not sure.

Heat is your friend when removing hardware with high-strength threadlocker.   

Finally got all the float bowl bolts out by gripping them with mole grips, pretty mashed up heaad now, im off to get some replacements now.

This still leaves the problem of the exhaust bolt, i cant get a good grip with the mole grips and putting an allen key in and hitting it with stuff wont get it to budge...  any ideas?, therewasnt any thread lock in the other bolts so im guessing there isnt any in this one...

Quote from: crazyfish on April 12, 2008, 05:40:37 PM
One of the bolts securing the exhaust to the cylinder head (the other three came out all right, but were still a bit rusty)

I removed my header bolts recently. I was lucky because they all came out easily. Before attempting removal, I applied "Liquid Wrench" (PB Blaster in the USA?) several times over the course of a week. I rode the bike in between so that penetrant would go through a few heat cycles.

You can read some suggestions in this thread:
http://gstwins.com/gsboard/index.php?topic=40522.msg455153#msg455153

Similar threads can be found at:

• http://gstwins.com/gsboard/index.php?topic=13775.0
• http://gstwins.com/gsboard/index.php?topic=29460.0

In the worst case, the head of the bolt can snap off and cause you some serious grief (and possibly expense) in extracting the remaining stud. Approach with caution!

And if you do get it out, replace all four bolts and apply anti-seize to them. I can only assume that the previous owner did this courtesy for me; the bike is 13 years old and I got the bolts out with a simple Allan wrench.