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Discussion Starter #1
Well, the time came to finally take apart the EX and play with it a little bit. After removing the seat, tank, fairings, etc I started to remove the battery. I noticed one of the bolts holding it on had already broken (leaving the threaded part still inside). Luckily part of the screws are hanging down below and I managed to use a pair of pliers and "screw" one out. The other isn't working so well, I seem to just be stripping the thread on the bottom. Can anyone help me with this, or is there a special tool designed for this? Thanks.

Nick
 

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Capo di tuti Capi
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Sears makes a special tool called 'Screw out' that removes stripped screws and bolts. It is a worthwhile investment.

Stone
 

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You can use a screw extractor. You drill a hole in the exact center of the bolt from above using a cobalt drill bit of the right size for the screw extractor you are using. Then you insert the screw extractor in the hole you bored and twist left. If all goes well, the screw comes out easily.

HOWEVER, it's easy to do it incorrectly and break the screw extractor in the bolt. Then you can forget about removing the screw from above. For this reason, I recommend using a screw extractor as a last resort and also recommend you leave it to a professional.

The screw extractor will cost about $3, the drill bit about $3, and the T-handle for the screw extractor about $6.

I recommend trying to use vise-grips. Be sure to use WD-40 or similar to lubricate the broken bolt's threads.
 

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Discussion Starter #6
Thanks for all the responses guys. I bought some lubricant and bolt extracting stuff earlier today, but haven't tried it yet (110* or so in the garage, ouch). I'll find some vice-grips and try that first, all three of these bolts are attached to the frame so I've got to get them out somehow. Thanks again for the advice.

nick
 

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If you can find it P.B. Blaster works much better then WD-40 for rusted bolts. If all other methods fail you can drill out most of the screw and remove what's left with a set of needle nose vice grips. Start with a small drill and work your way up trying to remove after you drill it each time. Then I suggest running an end tap throught the threads just in case some of them got nicked. Be careful though you can damage the threads in the bolt hole very easily using this method.
 
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