Stripped head on set screw

[1sttimeXSowner]

I'm not sure that's what you call them, but the bolt that has an inset hex head that takes an Allen wrench to loosen or tighten it anyway...the head on the one at the front of the left side rail on my XJ is stripped and I can't get the sucker to loosen so I can take the side rail off. Anybody got a good way to remove one that you can't get to the round head with vice grip pliers on?

[latexeses]

I'm not too sure what you mean by "rail" but there are some universal truths to freeing stuck fasteners.

First thing I would do is set the wrench in there that is supposed to fit and give it a couple raps straight in with a hammer to maybe free up the screw. To clarify. Hit the top of the screw a couple sharp blows. Make sure the screw doesn't have a bunch of crud in the bottom of the head where the wrench is supposed to go. If it does clean it out and then give the screw a rap or two or three.

That being done you might try getting an inch sized wrench that is a fraction larger than the striped screw and try driving it into the head of the screw.

If the screw head is exposed you can grab the head with a pair of vice grip pliers to turn the screw.

If the head of the screw is not set down in some aluminum part you could try some heat. Some one may have used permanent locktight.

If it still doesn't come loose, sell me the bike, ship it to California and I'll see what I can do.

A picture of the offending bolt might help.

[dbeardslee]

A couple more options...

You could try drilling it and using an ez-out. If there is enough head exposed you might be able to use a bolt out to get it. Craftsman has some nice ones -

[trbig]

I don't know what "Rail" he's talking about either, but you can also use a Dremmel with a cutting wheel and cut a slot in the top to use a regular screwdriver on.

After that, take the 5mm allen wrench you had that is more than likely rounded on the edges also.. and either throw it away, or grind it down a little at a time so as to not get too hot and remove the temper, up past the rounded spot.


Tod

[Ken Talbot]

the head on the one at the front of the left side rail on my XJ is stripped and I can't get the sucker to loosen so I can take the side rail off.

I think he's talking about the passenger grab rail on an XJ. IIRC, this fastener is inset a bit, making it a bit harder to get at if the socket is stripped. If so, a fine diamond burr in a dremel will cut a slot in the bolt head, allowing use of a flat blade in an impact driver to get it out.

[1sttimeXSowner]

Stripped Screw

Thanks guys....Ken is exactly right concerning the rail I mentioned--it's the passenger grab rail and the screw/bolt is inset.

[trbig]

Hmmm.. OK. Then take your SIX mm allen wrench and....




Tod

[1sttimeXSowner]

Hmmm.. OK. Then take your SIX mm allen wrench and....




Tod

Wow, thanks TOD...that helps a lot man....

[crazy steve]

A trick I've used a time or two where you have a recessed allen is to use a cheap/damaged allen wrench, insert in the fastener, then put a couple of heavy tack welds on. The heat will help loosen the screw, and you now have a handle. Of course, you throw away both items, but it's out...

To avoid arcing to something you shouldn't, cover around the area with duct tape, exposing only the bolt head.

'78E original owner

[Ken Talbot]

So, are you going to try the dremel to make a slot, then an impact driver?

[XSokieSPECIAL]

Hmmm.. OK. Then take your SIX mm allen wrench and....




Tod

Tod likes taking 6mm, 8mm, 10mm, or who knows what size he is up to now, and..................


(he's funny that way)

[1sttimeXSowner]

I think he's talking about the passenger grab rail on an XJ. IIRC, this fastener is inset a bit, making it a bit harder to get at if the socket is stripped. If so, a fine diamond burr in a dremel will cut a slot in the bolt head, allowing use of a flat blade in an impact driver to get it out.

Thanks Ken for the advice...did what you suggested and got it off.