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Stripped bolt under seat, can't access battery

7963 Views 13 Replies 8 Participants Last post by  eksine
Hey guys, I've had trouble with my battery lately, the ground connections tends to come loose causing the bike to die when I hit the starter button sometimes. Usually all I have to do it open up the seat and tighten it every once in a while. It's a PitA but it's doable until I can solve my issue with the connection coming loose.

My problem now is that one of the two bolts that holds the seat in place is stripped and I cannot remove it with the factory tool kits Allen Wrench. How can I get it off to replace the bolt and to get to my battery?


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Im not sure which bolt you mean, size or location. But in the past i have had some mild luck with screw extractor drill bits. I dont know if you have the space for that setup. Another thing if its really stubborn you can grind two sides of the head and form it into a square or rectangle and throw a crescent wrench on it. But again that requires space and an exposed bolt head. Be very careful if you go the grinder route. Sparks and such haha. Im sure someone else will chime in with more assistance.
Can you take a pic of the said bolt?
2
It's this one here


It's the bolt located underneath this fairing


I am currently trying to drill into it and get a screw in the I'll be able to back out and hopefully pull the whole thing out.

It uses the larger of the two Allen wrenches in the factory tool kit.


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Can you put a hex, one size bigger in the hole? Will it grab? If you can't get it to grab, you're going to have to use an extractor to get the bolt out. I use a HF extractor. http://www.harborfreight.com/12-piece-screw-extractor-set-40349.html

Drill the hole and make sure you can get one of your extractors in the hole. Take the extractor out. Heat the bolt, put the extractor back in and see if you can remove the bolt.
Can you put a hex, one size bigger in the hole? Will it grab? If you can't get it to grab, you're going to have to use an extractor to get the bolt out. I use a HF extractor. http://www.harborfreight.com/12-piece-screw-extractor-set-40349.html

Drill the hole and make sure you can get one of your extractors in the hole. Take the extractor out. Heat the bolt, put the extractor back in and see if you can remove the bolt.

I tried the next size up but no luck. I don't have one of those extractor tools but I am borrowing a Dremel from my uncle so I'll grind out a slot for a flat head screwdriver and hopefully that'll solve this. If not I'll be off to Lowe's for one of those.

Thanks for the help guys.


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Well nothing I was able to do today helped so I'm calling quits until tomorrow. The awkward placement and tough angles made it tough to get to with the Dremel. I'm just frustrated at this point so it'll have to wait until tomorrow.

Ugh


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Well nothing I was able to do today helped so I'm calling quits until tomorrow. The awkward placement and tough angles made it tough to get to with the Dremel. I'm just frustrated at this point so it'll have to wait until tomorrow.

Ugh


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How did you strip it? That bolt is not tight.
How did you strip it? That bolt is not tight.

Maybe I over tightened it last time I put the seat back on. Not really sure.


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Did you ever solve this issue? And what worked I currently have the same problem and nothing is working. Tried the suggestions above so I’m hoping whatever you did I can add to my list
Something else that has worked for me in this situation is to drill with left-hand drill bits, which will tend to loosen the bolt.

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That's a really easy fix just get a Dremel cut off wheel and cut a groove into the head. You now have a slot that you can use a flathead screwdriver to take it off. Don't make it harder than it needs to be this is like 10 minute fix
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