Right side cover bolt now stripped

[MrPepsi]

This started with this tread... http://www.zggtr.org/index.php?topic=2763.0
This is the painted cover that you must remove from the right side, before you can access the cover for the battery.
There is one bolt. Last time I removed it, it did not want to go back on easy. Well now it wouldn't come off at all. The alllen stripped in the bolt. Ideas? I tried cutting a groove to fit a large flat head screw driver, but the bolt is too soft to use a screw driver in. If I go to Kragen, what am I looking for to drilll into it?







I could really use some advice, I'd like to get it back on the road tomorrow.
I tried heat, I tried hitting it with a hammer.
It moved, but not much. Now I can't grip it with anything.

[Jeremy Mitchell]

An "Easy Out" would be your best bet IMO.  You should be able to find one at the local Lowes or Home Depot for around $10.

[ZG]

I saw on another thread recently somebody said to strategically weld a nut to it, I don't have a welder in my garage but maybe you do? 
 
Good luck MP, that sucks bro... 

[MrPepsi]

I'd prefer to use a whole lot of banned words right now, so read that frustration into this post.
I cannot for the life of me get this bolt to come out.
I have purchased an extractor, with no luck. Just spins.

[Flathead]

I'd prefer to use a whole lot of banned words right now, so read that frustration into this post.
I cannot for the life of me get this bolt to come out.
I have purchased an extractor, with no luck. Just spins.

The extractor or the bolt just spins? If the extractor, then you need to drill deeper. Be sure to tap the extractor into the hole with a hammer a bit to make sure it gets a good bite.

If the material is that soft you should be able to drill the head off and at least get into the panel.

May sound counter-intuitive but I've had pretty good luck removing stuck fasteners by tightening them a bit first. Of course, this is before it is stripped.

[Z71]

You do not want to weld anything to that bolt, or you will melt the fairing.  I do not know if this helps, but I ran into a similar situation on my Suzuki 1250 Bandit.  One of the clutch cover Allen button head bolts stripped and I ended up drilling it out by drilling away the entire head of the bolt.  It was somewhat of a chore, but it worked.

After you drill away the head, you can remove the fairing and then remove the rest of the bolt with a pair of pliers.

[MrPepsi]

Well at least its a start.
I can get to my battery now.

[jayke]

That bolt is tricky. It doesn't go in straight. It goes in at angle, that's why every one strips it out.

[MrPepsi]

That bolt is tricky. It doesn't go in straight. It goes in at angle, that's why every one strips it out.

Now you tell me

[VirginiaJim]

You and Lather should get together...but not on my bike. 

[CrashKLRtoConnie]

Not sure if there is a portable EDM electron discharge machine, that uses carbon electrodes and a fluid bath to etch metal.

Welding would likely damage the cover.

Perhaps grind the blot head off and then remove the cover. You may have the room to grab the bolt shaft with vice grips or similar. Or perhaps use penetrating old and or a torch to heat the thread joint.

On my 2008 I found all similar bolts would start to strip out ... I used a snap on torque wrench and good hex drive sockets so no over torque.

As it started to round the hex head slots, and before they got as bad as you had...

I bought new oem bolts and they seem to be made of lighter metal than I would expect from harden steel high grade bolts. The oem new bolts also had some dark red paste on the threads.

Best luck

[lather]

You and Lather should get together...but not on my bike. 

Yep, if you uptight guys were more like me you'd never have stripped bolts.

[ZedHed]

Once you get the rest of the bolt out, you're going to have to install a thread repair (Heli-Coil) so you can use the same OEM bolt again.  If you remove the plastic access cover you should be able to do the weld-a-nut procedure to remove the rest of the bolt.  If not, you have to drill out the the remainder and then heli-coil it.

[lather]

The OP's reply with photo at #6 is indication no further suggestions required.

[So Cal Joe]

The OP's reply with photo at #6 is indication no further suggestions required.

No, that just means he got it out. 

[lather]

No, that just means he got it out. 

Wouldn't be so bad if there hadnt been an almost identical thread like 3 days ago.

[VirginiaJim]

Such is life on ZGGTR.

[MrPepsi]

Wouldn't be so bad if there hadnt been an almost identical thread like 3 days ago.

Yeah sorry about, but it was a different bolt, made of different matierials.

[ZedHed]

The OP's reply with photo at #6 is indication no further suggestions required.

He didn't get the bolt out, he twisted the head of it off.  Bolt is still in the frame......

[lather]

He didn't get the bolt out, he twisted the head of it off.  Bolt is still in the frame......

You may be right but I was responding to the post suggesting grinding the head off.