Sheared bolt

[Edin430]

Trying to remove the petrol cap surround and one of the bolts is sheared therefore the allen key won't grip...

Any ideas how I can get it out??

[BiggestNizzy]

Drill it out - carefully

[Edin430]

I was hoping someone wouldn't say that.....

[BiggestNizzy]

Is the head off the bolt ? or has the hex just been rounded off ?

If you still have the head of the screw you could either ram a torx bit in it or use a small Spiral point tap and a hammer to remove it. this is more risky as a slip could end up being expensive.

To do it you hammer the spiral point tap into the screw so you have esentially a center dab near the outside edge to give you some purchase. then you use this to hammer the screw round.

If the head is off and it's stuck fast drilling is your only option.

[Edin430]

Just the hex has rounded off.... Everything else is still there. Allen key just spins round without catching it now!

[philthy]

Id go with a sligtly larger torx bit hammer into it, if not then use a drill.

I have some easy outs but they are almost always useless.

[espritstu]

hi use a good pair of vice/mole grips,adjust the tension and grip it tight as flat as possible so it marks the caphead then lever the grips Anti-clockwise too loosen,should loosen no problem.

[Edin430]

The problem I have is that its embedded down a bit into the filler ring, if that makes sense? So impossible to get anything round it.

Just had someone look at it and he thinks it's going to need drilled for sure which I'm not confident enough to do with it being so close to the clam

Going up to see Ali mid-week for quite a lot of mods so will just add it to his list of things to do

[BiggestNizzy]

is it a countersink ? and are you fitting a carbon fibre filler ring ?

I am a S1 owner and know very little about S2's

can you snap off the existing ring to releive pressure on the screw allowing it to come out easy ?

[robin]

Left handed drill bit in a reversible drill will also work. The hex hole that the allen key should go in will keep the bit from jumping out, but if you're in any doubt about your abilities to hold the drill in place, mask off the surrounding area with a something like an old tarpaulin with a suitable hole cut out of it ... use slow speed and lots of pressure. The screw will come out ... you could also tack weld some welding rod into the head (using an arc welder badly will have just this effect), assuming the screw is earthed.

If you prefer you can also use a normal drill sized to the diameter of the screw to simply remove the head. Once the rest is off, you can then clamp the screw shank with mole grips and it will come out.

Cheers,
Robin

[Rich H]

Please don't weld it. Normally yes, but given that its on the filler cap....

[Edin430]

Yes that it is being replaced along with many other things.. Thought I could handle this one on my own but clearly not

Too late to have a go now but will get pics up when I get time during the week and show you what I mean.

Thanks for the instructions Robin I'll definitely be masking it all off and covering with lots of towels just in case..!

[pete]

Yes that it is being replaced along with many other things.. Thought I could handle this one on my own but clearly not

Too late to have a go now but will get pics up when I get time during the week and show you what I mean.

Thanks for the instructions Robin I'll definitely be masking it all off and covering with lots of towels just in case..!

Dremmel a slot in to the bolt head if you can then use a screwdriver in it?

[Edin430]

Tried that already... Just kept making it worse!

Going to have a go at drilling the top of it, very very carefully.

First time I've actually done this so will see how it goes.

[robin]

Please don't weld it. Normally yes, but given that its on the filler cap....

It's fine if the fuel cap is in. In any case, unless your tank is almost exactly empty you won't have an explosive mixture in it.

Cheers,
Robin