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Stripped rear brake master cylidner mounting bolts!!

4110 Views 41 Replies 11 Participants Last post by  Veefer97
I have an 06 gixxer k6 and I stripped the shit out of these bolts trying to get them off:

They're only supposed to be torqued to 7 ft-lb per the service manual. But with their thread lock and the fact that they haven't been touched since mfg of this motorcycle they're practically welded in there.

They have a 4mm hex head which is tiny and didn't stand a chance with the force to get these off. I rounded the hole and the hex grip is gone.

Now I dremeled a nice slit to fit a flathead screw driver, but these fuckers won't budge. The flathead is stripping the slit and I can't get any leverage. They're mangled now and I think it's time for a screw extraction.

So 3 questions:

1) Does anyone have the size spec of these screw threads (width, length & thread)? Specifically the width so I know what size extractor bit to use.

2) Do you agree that it's time for a screw extract? What product is best and where to buy? EZ out? Home Depot? Auto store?

3) Extra opinions on this matter

:comp FUUUUUUUUUCK! :comp
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the soft bolts are soft so you don't over tighten them or they strip. not all tools are made equal. cheap tools will usually not have the tight clearances like expensive ones.
some of the best allen wrenches I've had are made by eklind.
Eklind Tool Company
You know, I agree with you sport-ryder. The medium and light duty bolts on these bikes suck so much. I really only feel comfortable reusing the higher quality bolts with deep & large allens and square drives. You can tell a quality reusable bolt just by looking at it.

The light duty ones, like the ones I stripped (4mm allen heads) look like you can almost chew them like bubblegum. Obviously it held like a motherfucker, but the head is so soft and cheap, I feel like it's counter productive to have something hold so tight with such a fragile head.

The replacements for these bolts is under $2 from Suzuki (which is overpriced OEM) - so that's how cheap they are. I would almost be inclined to get replacements from hardware stores like you mentioned with better drives.

The only problem I have with hardware stores here in the states is that they have more SAE bolts than metric. So you don't have a lot of variety on the metric side of things. Damn founding fathers SCREWED us (no pun intended) :lol
Try I use them for all kinds of hardware and other bits and pieces. Great selection of SS Allen bolts. You get your parts within a few days. Good company to deal with. Their catalogue must be over 2000 pages
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