Stuck again - Allen bolts in oil filter housing

[pete]

Hi all,

I'm once again stuck... trying to get the two allen bolts out from inside the oil filter housing on my '81 450.

So far, I've rounded the head of one allen key, twisted another, and I just also broke a special allen key head I got that fits a standard socket driver. Wonderful.

Has anyone had this trouble before and has any tips on how to get them out? This is the last bit stopping me from separating the crank cases.

And yes, I absolutely *have* to split them now as two of the other bolts have snapped halfway through the thread and I'm going to have some fun getting them out.

I've circled them in red below.

[pete]

So no one's had any luck even trying to get these out before?

[bwringer]

I've only dug into a GS850 engine, which does not have these bolts. If the other four cylinder GS engines also do not have these bolts, experience may be limited.

That sure looks like a toughie. My condolences.

If the bolt heads are well and truly expired, maybe you can drill the heads off with one of those right angle drill adaptors (mine was $12 at Harbor Freight) and a shortened drill bit. You might also be able to chuck up a drill bit in an air powered right angle die grinder, or use an abrasive stone to grind the head off. It'll take a long while, though.

Maybe cut a slot with a Dremel and use a large straight screwdriver bit?

If there's anything at all left of the heads, sometimes you can get a slightly oversized Torx driver bit into the head of a hex like this and get it to turn.

Just throwin' out some ideas...

[pete]

That'd be right, something "special" on the 450 :-)

The heads appear fine, not chewed or anything, just in really really tight.

26 years of holding the cases together I'd say.

I'm still doing some tool hunting too...

[chef1366]

Did you try heating around the bolt with a torch and tapping the bolt before trying to extract.

[pete]

I haven't, but mainly as it's alloy, so I didn't want to warp anything.

I have tried tapping with a hammer, but at the moment I've had to dodgy up a tool using an allen key and socket due to the bending and breakages of my tools...

[pete]

Ok, housemate just came back with another bit and produced his little blow torch, but no go.

Apparently his brother has a rattle gun though, so that's the next step.

I'm off to Melbourne with the Mrs on Thursday for a bit over a week, so with any luck when I get back, they'll be loose.

Then again, I won't hold my breath :-)

[gs650gt]

I have some experience of GS650 and I can tell those bolts are damn tight. What I needed in loosening was a socket wrench and a long enough extension socket.

good luck

[SqDancerLynn1]

What you might try due to the limited access, a SHARP chissel & hammer on the edge of the bolt

[pete]

Hmm... dunno about that, not because it's a bad suggestion, but because I can see great big marks from where I've let the chisel go off the head of the bolt... I'm not exactly handy with these sorts of things.

As it is, I won't get time until I come back from Melbourne, so I might keep this in mind as a last resort if I get back and the rattle gun hasn't worked :-)

[Tom MLC]

This may sound illogical. Try TIGHTENING first. Just a little. Sometimes it's just enough to break the crud off the threads. If it starts to budge, work the bolt out & in slowly, until you get it all the way out.

When you finally get them off, be sure to use anti-seize compound on the new ones.