Allen bolt will not come out!!!

[rob97xp]

Trying to replace the beeper in the handle bar cover on both GSI'S. The little Allen bolt that holds the finger throttle housing will not back out!!! She will turn out one or two turns and then just tightens up and will not back out.... any tips on how the get this thing out?????

 

[AdamXP800]

Why are you removing the throttle housing to replace the beeper?



96 XP800!
Keep the 2 strokes alive!

 

[rob97xp]

there is a screw on each side of the plastic handle bar pad cover that is under the throttle housing, and on the start button/vts housing.

 

[bajaman123]

I've seen that before...it can be a PITA. And if you strip out the head of the Allen bolt, all you can do is drill it out.
In cases like this, I've had luck by shooting some PB Blaster along the threads, then screw the bolt in and out repeatedly, backing it off a little more each time if you can. Sometimes there is just a burr on a thread or a bit of rust if the stainless bolt was replaced by someone.

Another thing to try is to simply use and electric impact driver to back it out hard and fast.

 

[gforney]

try a left handed drill bit after a good soaking of PB Blaster.

 

[pwgsx]

If its stripped try tapping in the next size allen bit or using a stripped screw extractor bit. If everything is turning, then the plastic that holds the bolt in the housing probably cracked and the nut is just spinning around.