Hi guys, been reading this forum for quite a while but now it's time to make a topic myself.

To check the valve clearances on my 2007 GS500 I was taking off the cylinder head this morning which has 6 bolts. 5 of them were easy to loosen (after initial cracking loose could be loosened by hand) but the one that sits most forward on the cover was really tight. Only with a long allen key did I manage to loosen it a bit but opposed to the others i couldn't loosen it easily after the first turn. I spend about 10 minutes making 1/8th turns since there is 0 room around that bolt before the head gave up and is now stripped. Not quite sure why that bolt is still so heavy to turn but I'll have to find a way to remove it since it's now about halfway out and I can't loosen or tighten it anymore. Does anyone have advice on how to remove this stripped bolt? The location means there is practically no access from the top making extraction tools hard to use. Hope anyone has had something similar before and can give some advice!

Ouch! In a pickle, can't go forward, can't go back, sympathy...

A few ideas:

1. Welding! A talented welder, usually a car repair guy with a Tig welder could weld a nut to the top of the bolt, then turn bolt out, remove. That's probably your best bet, but means finding someone nearby and transporting bike in a truck, unless you have a spare tig welder in your garage.

2. Grinding! I've got a pretty good air power die grinder with a carbide disc, would be tricky to fit in that small space, might need a smaller electric rotary unit with a carbide disc, grind away the top of the bolt; if you damage the top cover in the process, no big deal, plenty used parts available (I have a spare).

3. Driving a T40 Torx bit into the allen bolt hole and threading out, maybe applying some heat as well if the threads are sticking. This is what I do with the exhaust bolts that get stuck in the head, but there's room to hammer those in, not so much room for your situation, so I don't know how you might get the Torx bit to dig into the bolt.

Quote from: haybaler on January 29, 2025, 08:26:03 PMOuch! In a pickle, can't go forward, can't go back, sympathy...

A few ideas:

1. Welding! A talented welder, usually a car repair guy with a Tig welder could weld a nut to the top of the bolt, then turn bolt out, remove. That's probably your best bet, but means finding someone nearby and transporting bike in a truck, unless you have a spare tig welder in your garage.

2. Grinding! I've got a pretty good air power die grinder with a carbide disc, would be tricky to fit in that small space, might need a smaller electric rotary unit with a carbide disc, grind away the top of the bolt; if you damage the top cover in the process, no big deal, plenty used parts available (I have a spare).

3. Driving a T40 Torx bit into the allen bolt hole and threading out, maybe applying some heat as well if the threads are sticking. This is what I do with the exhaust bolts that get stuck in the head, but there's room to hammer those in, not so much room for your situation, so I don't know how you might get the Torx bit to dig into the bolt.

Thx for your advice! I was almost going to visit a nearby garage to ask for the welding when I noticed (though quite hard) it was possible to turn the bolt when gripped really tightly with water pump pliers. So I spent about 2.5h this afternoon making 1/16th turns in the limited space before the bolt finally came loose. So fortunately didn't need a weld in the end but thanks anyways, will remember it for next time!

Excellent persistence, hooray!

I can't find the 6mm allen socket  that I cut down, mated with a short throw 1/4" ratchet, I think you can get better access to that bolt and the two front corner bolts as well.

Let me know if you need replacement bolt(s); I can post to you tomorrow.

Cheers!

Quote from: haybaler on January 30, 2025, 12:11:07 PMExcellent persistence, hooray!

I can't find the 6mm allen socket  that I cut down, mated with a short throw 1/4" ratchet, I think you can get better access to that bolt and the two front corner bolts as well.

Let me know if you need replacement bolt(s); I can post to you tomorrow.

Cheers!

Modified ratchet sounds like a good idea for jobs like this, gonna look into that! I got some replacement bolts this afternoon, im pretty lucky to live in a small city with a bunch of car/motorbike garages within cycling distance. Judging by your timezone I think we're not on the same continent for shipping anyways (i'm in The Netherlands) but I appreciate the offer, cheers mate!

gently hammer it, tighten it a bit before loosening it. now you have it out it may be good to put anti seize on it. i always used loctite 
the oil under the shims will make a suction lock, using afiber to suck up the oil helps a lot