Triumphrat

07-31-2004

Trying to install a Throttlemeister on my '96 Trident 900 and the right-side Allen bolt on the original bar end weight is stuck and now stripped from my attempts to break it loose. I've tried drilling with a 6 mm tap and die bit. Maybe 6 mm is a little too large because I only manage to further destroy the capacity to use an Allen wrench on the bolt.

I've removed this bolt before, it must have some rust in it and I must have overtightened the last time I replaced the handlebar grips (earlier this spring).

I'd be most grateful for any recommendations about how to get this bolt loose...

Many Thanks,

j98sprint · 08-01-2004

Your local hardware or auto-parts store probably carries a selection of different size screw/bolt extractors. They're inexpensive and easy to use.

j98

GaryD · 08-02-2004

A little penetrating oil and an impact driver (when you hit the end, it turns) will loosen almost anything that isn't rusted beyond salvage. The impact lossens the threads. However, it sound to me as if you have one chance with a drill and a screw extractor before you have to almost completely drill it out.

I suggest you buy a full set of extractors as - if the first attempt doesn't work, once you get the head of the bolt/screw off and start drilling the shaft, you usually can get good oil penetration and a small extractor should then work on the shaft of the bolt alone.

dolson · 08-02-2004

Kroil is the best penetrating oil I've ever seen. Soak it and let it sit for a day or so and it should come out very easily,