Stripped...

[scott_araujo]

Big hammer and a torch.  You can get one of those nifty tiny butane models that has a very focused flame or just get a cheap standard propane model at the hardware store and be a little more careful.

Heat the head of the bolt, the heat will travel down into the threaded section.  Then give it the business with the big hammer and impact driver.  No combination like surgically applied fire and brute force.  Keep an extinguisher handy, I think some of the stock rearsets have rubber grommets that they mount with.

Scott

[marty_il]

i've found that lots of heat (as in, heating the bolt to a dull glow) + a driver hit with a 3lb sledge will work better than an impact gun. but mostly it's the heat.

if all else fails, just drill it out and either tap the new hole or use a helicoil. you've already wasted more time and frustration than it would have taken to do this.

[Chucko9-696]

If you have a TIG welder available weld a nut on the head and use a wrench 

[Artful]

I have a HF 4lbs hand sledge we call "Vlad the Persuader".

It tends to loosen a bolt right proper.

[the_Journeyman]

Been sick & busy, so I haven't been in the garage.  Currently, I've borrowed my dads air impact gun.  I'll at least try it.  I do spray it down with penetrating oil every day or two.  I'll get my hands on a big hammer. 

I am still fairly certain I'm dealing with a arched bolt shank that's creating the bind thats stopping the turning.

JM

[ducpainter]

Been sick & busy, so I haven't been in the garage.  Currently, I've borrowed my dads air impact gun.  I'll at least try it.  I do spray it down with penetrating oil every day or two.  I'll get my hands on a big hammer. 

I am still fairly certain I'm dealing with a arched bolt shank that's creating the bind thats stopping the turning.

JM

An air impact won't work the same...it will most likely strip the fastener head or break the socket.

It just twists...the hand impact driver twists and drives inward.

[scott_araujo]

I am still fairly certain I'm dealing with a arched bolt shank that's creating the bind that's stopping the turning.

Keep working it with heat and tools and impact.  Worst case the head snaps off and then you can drill what's left but you don't want to drill unless you have to.  If the rearset is trashed already you could cut that away from around the bolt to get more purchase on it.

Scott

[the_Journeyman]

It just twists...the hand impact driver twists and drives inward.

Yup, wound up finishing off one of them.

Still nowhere.  I'm hitting the hand impact driver as hard as I dare while the bike is on the stands.  The whole bike is wobbling around.  I don't have anything that can cut the rearset off.  I'm guessing that I'm heading toward drilling. 

I am attempting to drill with a small bit a hole into the one that won't budge at all.  I'm thinking that if it'll relieve some pressure and allow me to heat deep into the bolt.  We'll see where than gets me ~

JM

[cakeman]

Geeeeeee... just reading this thread......... My Rizoma rearsets should be arriving any day now. For my 2004 S4R with 35,000km on it! After seeing this, im scared shitless..... i was just going to use a L shape Allen Key to loosen the bolts.... is this the right way to approach it.... I dont want to end up like Journeyman (poor fella, i feel for you!)

Any tips on how to attack this from the start?

[Howie]

A quality allen socket is a good start.

[cakeman]

A quality allen socket is a good start.

So no allen key??

[scott_araujo]

Does the bike ride?  You can always find a local machine shop and bring it to them.  They have tools and experience you don't and usually don't charge much.

Scott

[Howie]

So no allen key??

Good tools are your friends.  A good socket on a ratchet or an allen T wrench will give you more leverage and control.  If the fastener is not corroded or overtightened the allen will work. 

[DarkStaR]

Are you sure your turning it the right way?   ...Just kidding...  ...kinda...   

[the_Journeyman]

Time for an update.  When in the teens in the garage, I had to put this off a little while. 

Geeeeeee... just reading this thread......... My Rizoma rearsets should be arriving any day now. For my 2004 S4R with 35,000km on it! After seeing this, im scared shitless..... i was just going to use a L shape Allen Key to loosen the bolts.... is this the right way to approach it.... I dont want to end up like Journeyman (poor fella, i feel for you!)

Any tips on how to attack this from the start?

Unless yours are over-tightened or stuck, an allen socket or wrench will be fine.

Currently, I have the rearset off, BUT the bolts are still stuck hard and fast.  At least I've got something to grab now and work with.

Does the bike ride?  You can always find a local machine shop and bring it to them.  They have tools and experience you don't and usually don't charge much.

Scott

Nope, on front & rear stands in the garage with no wheels mounted.

Here's what I did.

1.  Got a 1/2" bit & drilled the caps off the bolt.  See example.  This left the majority of the bolt and allowed removal of the rearset.



2.  Slid the rearset off, leaving behind the kickstand bracket and exposing the shank of the bolt.



Now, I just need to get a grip on the exposed shank and put some serious pressure on them and hopefully not snap the rest of the bolt.  We'll see.  I put my largest pair of channel pliers on them and got nowhere.  It just slid right off.  Another dose of PB and I'll try again later.

JM