What to do about stripped out hex bolts?

Question

My key wasn't working very well when I bought my motorcycle (Honda CB919/Hornet) and has continued to get worse. I bought the set of replacement gas tank lock, seat lock, ignition, and key. When I went to remove the two hex bolts holding the ignition on, I noticed that the numbnuts who owned the bike before me had completely stripped them out.

I don't really want to take apart the entire front of the motorcycle to get them out, but it looks like I'll have to. Is this feasible for a guy (non-mechanic) with a toolbox and a drill? Should I drill off the heads, move the ignition off and take out the bolt stems with pliers, or drill a hole into the bolt and use a reverse-threaded bit... or what? (then I'll have to get compatible bolts somewhere like Home Depot because I don't want to bother trying to get new ones from Honda)

Answer 1

Drill a hole in the center of the bolt head, then use one of these:

http://www.northerntool.com/webapp/wcs/s...

Use the drill bit size stamped on the tool

Answer 2

Guess what.  You are tearing it apart.  And numnuts used SAE wrenches instead of metric. and you want to do the same thing.   You go to HONDA and you get the proper bolts and the proper sized wrench and Keep it in your motorcycle toolbox with your tools.  For not only is the wrench metric, the threads are metric....and you don't go "close enough"

Maybe you need an "easy out" - it still means drilling a hole in the centre of the bolt(ask them before you buy the tool) .  If you can't do it, give it to a motorcycle shop(does not have to be Honda)  They will know how to do work on other motorcycles.

Answer 3

Get yourself  a set of s***w extractors: 1 find the right size extractor that would fit  2 center punch and drill hole in center of bolt  3. spray with oil / wd40 .... let it penetrate  3  use extractor to unscrew the bolt

If the hole goes thru, you can try to grind the head off and drill thru and re tap the hole

Answer 4

I used a Craftsman bolt extractor kit  (#52155) and a pair of vise grips to get a broken 6mm bolt out of a tight spot. Since, in your case, the bolts aren't broken off flush it should be relativly easy to remove them.

Answer 5

if your going for ignition bolts your going to have to take the front end apart either way won't you? Maybe if they weren't stripped you could do the good ol' had contort with a socket wrench but I doubt it.

Once you have it apart just vice grip the stripped heads and twist, if that doesn't work try the reverse threaded bit, and if that doesn't work drill the heads off.

I hate when this happens to me, I once stripped off a speed sensor bolt and had to take it to the dealer to have them drill the ***** off!

you should have just had a new key made instead of changing all the locks, it's probably just a worn key.

Answer 6

Hmm...I'm guessing that maybe you should take it to a professional...LOL  **wink**

Answer 7

When the action of the key in the cylinder gets worse over time the most likely cause is no lubrication. Buy a can of LockEase or a tube of dry graphite and lube the cylinders.  Try it now and you may not have to replace the cylinders.

DO NOT cut the heads off. DO NOT try to drill it out. It's guaranteed you will damage the threaded hole.

If the  threads on the bolts are stripped why not pull them out as is? Put a ratchet and socket on it and get some leverage behind the head with a screwdriver. While trying to force the bolt head out with the screwdriver, turn the ratchet at the same time. You may need to sharpen the screwdriver tip and tap it in behind the head to get it moving  out. Or you could use some type of tool that has a V shaped opening to get behind the head. An upholstery tack remover, or a small nail rermover may work too.

If the hole threads are stripped, you will need to either replace them with a Helicoil, or use the next size larger tap to change the bolt size. Helicoil is first choice.

Answer 8

Drill out the old ones and helicoil the holes and put in new bolts

Answer 9

i have a set of bolt removers that you pound onto the ouside of the stripped bolt, then they bite in and take the bolt out..

good luck

Answer 10

reverse cutting drill, plus maybe an "easy-out"