Hey all,

I was following the Haynes' manual and the steps on http://k.udg.edu/~m/reparacioGS500/forkseals/index.html to go about doing the fork seal change, when things went wrong. This page by Marc says that while removing the fender support, the screws marked 2 in this pic--> http://k.udg.edu/~m/reparacioGS500/forkseals/forkseals50.jpg might get locked and rounded. That's exactly what happened.

Now, I've got a screw extraction set, but it hasn't been working out well. The bolts are really stuck, and it seems my best option now is to just drill a hole, get rid of the threads, and put in a slight larger dia bolt. I'm not confident about whether that's advisable, so I was wondering if anyone had tips about this.

(On a related note, I was attempting to make a time-lapse video of the whole change up https://lh3.googleusercontent.com/-AT_KPN6NfQ8/TqQjT6dfGYI/AAAAAAAAQvk/ok4vSsb7fdE/s800/11%252520-%2525201.jpg but stopped after I ran into this locked bolt problem. argh!

I also pumped up the brake lever to "see how the brake works", like a dork, and managed to lock the pistons. Looking for a C-clamp now. Things are just not going right with me and my bike)

I'd first try slotting them with a hacksaw, then knocking them loose with a manual impact driver like this, if you have clearance for it. This is my go-to tool for crusted in bolts on Al blocks:



Otherwise you'll need to drill them out and/or knock off the heads. At least you're rebuilding the fork anyway, so you'll be taking it apart and at that time can drill / rethread the holes.

Assume you're already dowsed them down with a good penetrating oil.

I had the same thing happen to me.  I used a dremel tool with a cutting dsk and cut a slot in the head of the bolt for a standard screwdriver.  I replaced all of them with stainless units.

Use a screwdriver or something similar to gently pry the brack pads apart.  I've had them close up just sitting overnight.

I had them locked on one bike.
Put PB Blaster on for a day. Then used a torch to heat up the fork so the screw hole expanded and it freed the screw and it came out real easy.