Stripped and stuck allen bolt

[LabidySabidy]

Hey fellow Yamaha owners. I've had the worst week trying to remove the top allen bolt of the cct. The lower one is removable, but the top was stripped to begin with as well as tightened too much. In the process of trying to remove it I've rounded out the insides as well as attempted to make slits so that I may place a flat head but it just wont seam to budge.

https://drive.google.com/file/d/0BzP...VlbngtaFE/view
(bolt looks worse now)

I cant fit vice grips in this gap, but I was wondering if I could remove the bolt attached to the engine right above the cct without having any issues. Then I believe Ill be able to fit the vice grips and hopefully remove it. Any suggestions would be appreciated and an answer to this question would also be.

Thank you
Regards, Kasim

[donebysunday]

Impact driver if you have room ? Might need to re-new the slot you made to provide enough grip for a slot type driver for you impact.

Hey fellow Yamaha owners. I've had the worst week trying to remove the top allen bolt of the cct. The lower one is removable, but the top was stripped to begin with as well as tightened too much. In the process of trying to remove it I've rounded out the insides as well as attempted to make slits so that I may place a flat head but it just wont seam to budge.

https://drive.google.com/file/d/0BzP...VlbngtaFE/view
(bolt looks worse now)

I cant fit vice grips in this gap, but I was wondering if I could remove the bolt attached to the engine right above the cct without having any issues. Then I believe Ill be able to fit the vice grips and hopefully remove it. Any suggestions would be appreciated and an answer to this question would also be.

Thank you
Regards, Kasim

[bikerphil]

Yes, you can remove the nut directly above the tensioner, it is just a minor fastener for the cylinder head, when re-tightening it, torque to 14 ft/lb IIRC.

[LabidySabidy]

Thanks sunday. Ive been told thats an effect method but ive never used one nor do I own one. But I found out home depot rents them out so ill give it a shot tomorrow. But since I can safely remove the bolt above the cct I suppose Ill try the vice grip method again. Thanks for the great info Phil!

[bikerphil]

You're welcome, good luck!

[donebysunday]

It'll happen for you, you are determined !
I would also mention that keeping everything in time is so important, if your changing out the CCT. I've not done it so the advice you get from the listers and threads on this require complete comprehension.
I don't understand how so many have bent valves changing to the ACCT ?
Like I said, I've not done it ,,,,, yet.
Luck to You ! Done

[motoman]

Hey fellow Yamaha owners. I've had the worst week trying to remove the top allen bolt of the cct. The lower one is removable, but the top was stripped to begin with as well as tightened too much. In the process of trying to remove it I've rounded out the insides as well as attempted to make slits so that I may place a flat head but it just wont seam to budge.

https://drive.google.com/file/d/0BzP...VlbngtaFE/view
(bolt looks worse now)

I cant fit vice grips in this gap, but I was wondering if I could remove the bolt attached to the engine right above the cct without having any issues. Then I believe Ill be able to fit the vice grips and hopefully remove it. Any suggestions would be appreciated and an answer to this question would also be.

Thank you
Regards, Kasim

Snap a pair of vice grips on ouside of allen bolt and give them a tap on end with a hammer.............lefty-loosey.

[LabidySabidy]

The magical vice grips have failed me Oh well I suppose patience is a virtue. Thanks for the tip sunday, I'll be swapping it to an acct and will be taking all the necessary precautions to ensure all goes smoothly.

[DeanR]

Rent an impact driver? buy one, they're cheap! Thought the vise grip might work...Good luck.

[TADracer]

First, I would clean the motor off thoroughly and remove all that grease and build-up.
Second, I would make sure the motor is in the correct position on the timing plate for removal of the CCT.
Third I would remove the exhaust and get it out of the way if possible.
Fourth I would apply a bit of heat using a propane torch to the boss on the motor where the CCT is bolted (not to the CCT body) this expansion might crack the corrosion holding the bolt threads tight.
Fifth I would try to use a bolt extractor (I know Irwin makes them) to bite into the stripped allen head and remove the bolt. You might also find something like that at Harbor Freight or perhaps an auto parts store.

Best of luck to you

[BA80]

Best tool in the tool box. http://www.lowes.com/pd_577634-281-3...11480002581652

[HalfCentury]

In my opinion, the best investment ever is a spray can of Kroil. Spray where the bolt enters the threaded hole. Come back in in an hour and spray it again.

All of the rust will drip away and the bolt will come out.

[crazy steve]

Two last-gasp shots for removing that bolt...

One, just drill the head off the bolt; use the largest drill that will fit into the hex hole. This will leave about 1/4" of bolt sticking out once the CCT is out, apply vice grips. Still a bit risky as the you can damage the stub to the point where you will have issues in 'working' it...

Two, get a sacrificial allen wrench (the largest that will fit), tap it into the hole then weld it to the bolt head. The heat will help loosen it, and the wrench will let you turn it out.

Actually, there's a third way too. Do number one, but rather than vice grips, drill out a nut of the right size, push it onto the stub and weld the nut to it.

[Rettic]

I use a star drive the next size up and hammer it in to the Allen bolt. It holds tight enough it usually takes a hammer to get the star drive back out.

[motoman]

Again, snapping a pair of vice grips on allen bolt end, then tapping vice grips lightly with a hammer shoukd release allen bolt,