Bandit Woes

Any questions and problems about your motorbike? Ask other members for help and advice.
User avatar
caveman
Posts: 30
Joined: Fri Feb 05, 2016 7:54 am
Gender: Male
Bike(s): ZX7R, Xj550, XV1100, Bandit 6
Location: Aberdeenshire
Has liked: 3 times
Been liked: 5 times

Bandit Woes

Post by caveman » Sat Oct 17, 2020 7:36 am

I am looking for a little inspiration on removing stubborn header bolts on a bandit 600.

The bike is currently being stripped down to the bare frame for powder coating. However getting the exhaust detached has become a mission.
The previous owner obviously struggled to remove it in the past and gave in, The muppet welded the can, link pipe and headers as one.

I would like to save the headers and don't relish the though of drilling them out, if they can come out clean it would be fabulous!

The butter bolts are so far gone that no Allen key will ever fit them, so far I have managed to remove 6 of the 8 with a varying techniques. locking pliers on the ones that are accessible, welding nuts onto others and cutting groves into others. I have even uttered the magic words...move ya ba$%ard!!!

Sods law would have it the last ones are the top 2 which are a bit deeper and hard to get to.

Any suggestions or removing them would be greatly appreciated.
headers.jpeg
You do not have the required permissions to view the files attached to this post.

User avatar
Mr Fro
Subscriber
Posts: 6313
Joined: Wed Aug 28, 2013 1:03 pm
Gender: Male
Bike(s): ZX6r, ZXR750L Turbo
Location: Bury st Edmunds-ish
Has liked: 33 times
Been liked: 971 times

Re: Bandit Woes

Post by Mr Fro » Sat Oct 17, 2020 8:57 am

I've had luck on stuff like that by hammering in slightly oversized torx bits.

User avatar
Tiggie
Moderator
Posts: 4250
Joined: Mon Oct 10, 2011 7:46 am
Gender: Male
Bike(s): Nothing :-(
Location: Bingley, West Yorkshire
Has liked: 1731 times
Been liked: 1765 times

Re: Bandit Woes

Post by Tiggie » Sat Oct 17, 2020 9:00 am

I gave up trying to remove them on my old intruder. I rounded them out into two little perfect circles using my impact wrench :oops:

Drilling them out was the only option and I couldn't be arsed :lol:
Get your official TMBF snood/buff here:
viewtopic.php?f=6&t=73218

Play nice or I'll wake Rennie up. And nobody wants that!!

TimR
Posts: 1855
Joined: Fri Sep 16, 2016 7:48 pm
Gender: Male
Location: Didcot
Has liked: 35 times
Been liked: 565 times

Re: Bandit Woes

Post by TimR » Sat Oct 17, 2020 9:36 am

Dremel like tool cutting heads off at least gives you some stud to purchase on after headers removed.

Drill the heads off with increasing larger drill bits again allow s some stud to remain.

Would suggest hammering torx fitting in there bit if they are that tight then i doubt it will do anything
The woods are lovely, dark and deep,
But I have promises to keep,
And miles to go before I sleep,
And miles to go before I sleep.
Robert Frost

fastbob
Posts: 7799
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): Harley Davidson 1200 Roadster and another ER5
Location: Coventry
Has liked: 3092 times
Been liked: 3823 times

Re: Bandit Woes

Post by fastbob » Sat Oct 17, 2020 11:08 am

You seem to have covered every technique I was going to suggest other than take the heads off , remove the exhaust and use a stud extractor . However , having just broken a new 8mm stud extractor trying to get two exhaust studs out of my ER5 , I'm hardly in a position to recommend this option really . There are different kinds of stud extractor but options are limited in such a confined space . I haven't tried this type yet so I might give them a go . I think you could leave the heads on the bolts with this thing or something of a similar style .
https://www.ebay.co.uk/itm/252574416185

WD-40
Posts: 376
Joined: Thu May 14, 2020 11:55 am
Has liked: 35 times
Been liked: 193 times

Re: Bandit Woes

Post by WD-40 » Sat Oct 17, 2020 11:32 am

If you can weld I think that is the most effective way to get a stuck bolt out. If you get a washer and a nut with an inner diameter greater than the outer diameter of the stuck bolt so the nut and washer fit over the stuck bolt and then weld the whole lot together. Work the bolt back and forward. If the weld breaks do it a few times and hopefully the heat cycles will break the bolt free.

User avatar
Bender
Moderator
Posts: 5300
Joined: Fri Apr 21, 2017 6:22 pm
Gender: Male
Has liked: 2147 times
Been liked: 2494 times

Re: Bandit Woes

Post by Bender » Sat Oct 17, 2020 11:46 am

Drill die grind tops off if hammering something into them won't work. Get rid of exhaust see if you have room then to put a nut over the stud and weld it on
Bite my shiny metal ass..

fastbob
Posts: 7799
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): Harley Davidson 1200 Roadster and another ER5
Location: Coventry
Has liked: 3092 times
Been liked: 3823 times

Re: Bandit Woes

Post by fastbob » Sat Oct 17, 2020 11:46 am

Good point about working backwards and forwards . 👍

User avatar
Swagman
Subscriber
Posts: 994
Joined: Fri Apr 27, 2012 9:56 pm
Gender: Male
Bike(s): 2003 Yam Fazer1000 +2007 Fz6
Location: Torksey Lincs
Has liked: 218 times
Been liked: 627 times

Re: Bandit Woes

Post by Swagman » Sat Oct 17, 2020 12:34 pm

Weld the Allen key in the hole.

fastbob
Posts: 7799
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): Harley Davidson 1200 Roadster and another ER5
Location: Coventry
Has liked: 3092 times
Been liked: 3823 times

Re: Bandit Woes

Post by fastbob » Sat Oct 17, 2020 1:32 pm

Swagman wrote:
Sat Oct 17, 2020 12:34 pm
Weld the Allen key in the hole.
Good idea . Or weld an Allen socket so there's less effect of torsion .

fastbob
Posts: 7799
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): Harley Davidson 1200 Roadster and another ER5
Location: Coventry
Has liked: 3092 times
Been liked: 3823 times

Re: Bandit Woes

Post by fastbob » Sat Oct 17, 2020 1:37 pm

Hello ......https://www.halfords.com/tools/hand-too ... jcQAvD_BwE Or this one . I wish I'd known these existed years ago . Just never occurred to me . https://m.ebay.co.uk/itm/Q3-Damaged-Dis ... 2ff3d21d7d
.
You do not have the required permissions to view the files attached to this post.

User avatar
caveman
Posts: 30
Joined: Fri Feb 05, 2016 7:54 am
Gender: Male
Bike(s): ZX7R, Xj550, XV1100, Bandit 6
Location: Aberdeenshire
Has liked: 3 times
Been liked: 5 times

Re: Bandit Woes

Post by caveman » Sat Oct 17, 2020 2:15 pm

Cheers guys... :cheers:

Some good ideas there, I think i will give the Halfords Allen extractors a try and see if they can get a decent hold, otherwise its gonna be the drill.
failing that its knocking the bolt heads off and removing the stubs later......and if none of that works I will get the missus to shout at it!.

For the moment i have stepped away from it....and give it the occasion glancing dirty look when passing.

I managed to get a couple of the others out with this contraption, before space became an issue.
You do not have the required permissions to view the files attached to this post.

fastbob
Posts: 7799
Joined: Sat Sep 03, 2016 1:42 pm
Gender: Male
Bike(s): Harley Davidson 1200 Roadster and another ER5
Location: Coventry
Has liked: 3092 times
Been liked: 3823 times

Re: Bandit Woes

Post by fastbob » Sat Oct 17, 2020 4:12 pm

Walking away is often a winning strategy where stuck bolts are concerned . Things can look very different in the morning .

skyrider
Posts: 3123
Joined: Fri Jan 18, 2019 7:12 pm
Gender: Male
Bike(s): yamaha 225 serow
Location: preston lancs
Has liked: 395 times
Been liked: 786 times

Re: Bandit Woes

Post by skyrider » Sat Oct 17, 2020 7:25 pm

you could aways give them a good spray with plus gas leave them for a few days and then try again, it worked for me on the cb 500 manifold bolts
the law in all it's majestic equality forbids the rich as well as the poor to sleep under bridges to beg in the street and to steal bread.
anatole france

User avatar
caveman
Posts: 30
Joined: Fri Feb 05, 2016 7:54 am
Gender: Male
Bike(s): ZX7R, Xj550, XV1100, Bandit 6
Location: Aberdeenshire
Has liked: 3 times
Been liked: 5 times

Re: Bandit Woes

Post by caveman » Sun Oct 18, 2020 8:21 am

I have never heard of plus gas before, but look like It might just give it the edge I need with the Allen extractors.

I will place an order this morning and should be here mid week. Then let them soak for the rest of the week before having another crack.

Return to “Pitstop”

Who is online

Users browsing this forum: CommonCrawl [Bot], Trendiction [Bot] and 9 guests