Headlight bolts rounded off

[Doovy]

Well, due to the numpty that put on the dominator headlights onto my hornet (before i bought it), the bolts holding the headlights in are rounded off.

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0NjUtMjAxMDEwMTQtMTMwNy5qcGc.jpg

I want to fit a screen, which mounts in between the headlight bracket and headlights, with the bolt holding it all in place. I also have new bolts ready to go in, i just need the old ones out!

ideas please?

I have thought of cutting a groove into the bolt head (i dont have a dremel though) and trying to undo it through that.. might try later with a small saw but dont know if it will get to it. dont want to try drilling really..

thanks in advance
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Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[Syris the Indomitable]

I have issues with this in the pasts. The easy way out with a bit of elbow grease would be to buy a good quality needle file, file to parallel flat spots on opposite ends of the nut then use a small Stilson wrench to release. https://www.google.co.uk/products?hl=en&q=Stilson+wrench&um=1&ie=UTF-8&ei=Y9HCTKTzDYyC4Aaq2-i5Aw&sa=X&oi=product_result_group&ct=title&resnum=3&ved=0CBwQrQQwAg

Other than that it's drills taps and dies.
That needle file in tool box has saved more times than I care to remember.
Good luck!

You could even file a groove straight through the middle and use an impact screw driver. Another tool that has saved me loads of times.

[willi]

drill a hole straight into the center and buy a easy out.
are you sure you cant get a allen or hex key to grab there? appears to be enough to grab onto!
they are only soft bolts you could use a old flat screw driver and hammer by hitting the side of the bolt with screw driver and tap it around with the hammer.you will need to cut into the side of the bolt so the screw driver bites in while you hit it with the hammer.
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

wat goes around comes around.

[Vincent]

You might be able to wedge the right size torx head in there.

[nowhere.elysium]

[Vincent]

The only problem you'll have with he torx is getting the headlight bracket to stay still while you knock the torx head into the bolt.

[nowhere.elysium]

[Doovy]

thanks for replies everyone.

turns out the one in the picture had just enough left to turn with the right size allen key, but the other one is really rounded.

i have tried a junior hacksaw but due to bracket positioning and indicator placement it's not really possible.

have tried the screwdriver / hammer combination too but not really got anywhere (didnt really give a proper go)

will go for the torx bit idea! thanks nowhere.elysium, i'm slightly disturbed by your knowledge of my limberness.. perhaps i drank more that night than i remember..

good times


back off the garage....


____________________
Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[Doovy]

fail.

headlight bulb now blown.

the bolt still wont undo.

and the screw to undo headlight front cover to replace bulb is all rusted up and thread gone too.

taking to bike shop next week anyway for some crash repairs so get them to do this at same time.

i cba for this, i've got a dissertation to write lol
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Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[Doovy]

well i had another bash at it this evening.

with the help of my friend, Mr Dremel (borrowed)

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0ODMtMjAxMDEwMjMtMjAzMC5qcGc.jpg

resulting in this

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0ODktMjAxMDEwMjMtMjE0OS5qcGc.jpg

which allowed me to put on this (screen)

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0ODctMjAxMDEwMjMtMjE0Ni5qcGc.jpg

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0ODYtMjAxMDEwMjMtMjE0Ni5qcGc.jpg

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0ODgtMjAxMDEwMjMtMjE0OC5qcGc.jpg

excellent

also have to change the bulb on the left side, but that's an easy job.
____________________
Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[c_dug]

Your bike has a 'fro.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Doovy]

y'get me.
____________________
Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[Walloper]

Awe shite...

I just saw this thread and was about to suggest breaking a hacksaw blade to make a slot in the head so you can attack it with a big effin screwdriver but the Dammed Dremel got there first.
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W-ireless A-rtificial L-ifeform L-imited to O-bservation P-eacekeeping and E-fficient R-epair

[Robby]

I bet you went and put the knackered bolt back in there. Get a decent one to replace it before it seizes in place and you need to drill it.

Also, the screen looks a bit shit. I presume it's designed for a round headlight, hence the yawning chasm between the light and screen. Not too great for wind deflection either.

[Walloper]

Photo quality Fail.
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W-ireless A-rtificial L-ifeform L-imited to O-bservation P-eacekeeping and E-fficient R-epair

[Vincent]

[Walloper]

[Vincent]

Looks good waloper but might be a drain on the battery

[Walloper]

[Doovy]

[nowhere.elysium]

[Doovy]

very funny for the black metal innuendo

oh and just to prove i'm not as much of a 'bodge-er' as i used to be...

https://i2.photobucket.com/albums/y41/doovydoo/utf-8BSU1HMDA0OTItMjAxMDEwMjQtMjA1MC5qcGc.jpg

new headlight bolt (both sides too!!)

and i've just sent a PM to a guy on hornets nest regarding a standard headlight. woop.
____________________
Yamaha RXS 100 > Honda CD 250 > Honda Hornet 600 > Honda CBR 600RR > Yamaha RXS 100 > Kawasaki ZX6R J2 > Yamaha FZ1

[tahrey]

excellent. Good work with the dremel too.

Allen bolts are shite and used in far too many places (they're good for tight spots where a hex-head wouldn't work, but as demonstrated this clearly isn't the case for headlamps). I think I've come across almost as many rounded out ones as those which actually work.

My favourite is the torx trick, or in moments of desperation and severe rounding, abusing a spline bit. Had to do it only a couple days ago in fact, when hacking an old back-projector display unit apart to recover its tasty multipurpose guts. Torqued up to about five thousand newton meters AND with threadlock on a 5mm allen. Nothing doing.

Get a suitable size torx in there (one that JUST ekes into place), the spiky bits fit into the corner notches of the allen socket, but can't move along the flat bits, and the much sharper profile means they dig into the friable metal and stick well enough to turn the bolt, rather than filing it away and making things worse. Devil of a job to free the bit from its cold weld of course (mole grips & stuff), but worth it.