[TarzanBoy]

I have been trying to remove the shear bolts from the upper triple of my 2004 R1. I've had absolutely no success so far. I don't care about the old ignition because it has an intermittent short that causes the motorcycle to shut off randomly.

These bolts just won't budge.

First I drilled into one of the bolts and attempted to use a #1 screw extractor. I got the screw extractor in pretty far but ended up breaking it off in the bolt.

Next I tried using a chisel and punch to rotate the bolt. It didn't move.

The next day at work (which is today) I started to grind the ignition off, but realized that I would still have to deal with the bolts after, so I used the grinder to make slots for a flathead screwdriver. They didn't budge.

I tried using kroil oil and letting it sit for an hour –the bolts wouldn't budge.... even when I used a vise and adjustable wrench for torque.

I used a heat gun to head up one of the bolt housings, still wouldn't budge.

I have no idea what to try next. Even if i grind off the ignition and leave the bolts intact, I doubt i'd have any better luck trying to unscrew them from the shafts

 

[buechler5]

Use a hand impact driver with a flat head bit. Believe that’s what I did


Sent from my iPhone using Tapatalk

 

[BournR1]

You won't be screwing those out, they are rivets. I cut mine off with a metal grinder.

 

[andrewstclair]

they have loctite in there so you aren't getting it out like that. i typically centre punch then use a large drill bit to just drill till the cap pops off. the ignition will come off and then you are left with the exposed bolt threads. put it into a vice with soft jaws and apply heat with a propane torch and use vice grips on the thread thats exposed there should be plenty.

 

[alanmyers]

Yeah man. I feel you. I tried heating to no avail. I decided to just use another top yoke with a new ignition. Decided this was one battle that wasn't worth it. If I buy anything to help to get those out why not just a new top yoke, was my thinking. Not much more money. There are actually some really cool aftermarket top clamps on ebay for like $50. I can attest they align and work properly. Would look brand new and stylish. Or just get someone else's.

 

[John K]

I have been trying to remove the shear bolts from the upper triple of my 2004 R1. I've had absolutely no success so far. I don't care about the old ignition because it has an intermittent short that causes the motorcycle to shut off randomly.

These bolts just won't budge.

First I drilled into one of the bolts and attempted to use a #1 screw extractor. I got the screw extractor in pretty far but ended up breaking it off in the bolt.

Next I tried using a chisel and punch to rotate the bolt. It didn't move.

The next day at work (which is today) I started to grind the ignition off, but realized that I would still have to deal with the bolts after, so I used the grinder to make slots for a flathead screwdriver. They didn't budge.

I tried using kroil oil and letting it sit for an hour –the bolts wouldn't budge.... even when I used a vise and adjustable wrench for torque.

I used a heat gun to head up one of the bolt housings, still wouldn't budge.

I have no idea what to try next. Even if i grind off the ignition and leave the bolts intact, I doubt i'd have any better luck trying to unscrew them from the shafts
View attachment 1027883

I've used screw extractors......drill it , warm it up , seat the extractor, and remove them ...... they can be a hassle .

 

[NMdesertracer]

With a dremmel tool and a cutoff wheel you could grind off the bolt heads from the open sides

 

[YZF_RUQUS]

They make a very wonderful tool. it allows you to strike it with a hammer, and during this same instance, the tip of it twists. I believe this will save you.

 

[Numbers]

3 choices, 1 buy a new lock set like the op did. 2 drill them in a press. 3 hire it out to a machine shop.

Just for posterity.

 

[dcase4246]

3 choices, 1 buy a new lock set like the op did. 2 drill them in a press. 3 hire it out to a machine shop.

Just for posterity.

They can be a PITA...I would go with option #2

 

[BournR1]

Yeah, now that I think about it, I drilled them out. Then i cut the metal off where the ignition was on the triple clamp with a grinder using a metal cutting disc. Turn bike on now using Woodcraft ikeyswitch elimination harness. Here is pic of final result.

 

[Windsor1]

I used a drill press and drilled them out. You can also grind off the entire head, that will free it up.

 

[TarzanBoy]

I ended up using a dremel with a grinder attachment to grind the ignition off of the bolts (since the ignition was malfunctioning and thus not needed). Unfortunately I had to use wireless dremels since that is all i had access to (unless i wanted to purchase one), and the batteries kept dying on me.

After cutting the ignition off I was still left with the bolts which wouldn't budge. I ended up setting my kitchen oven to 550 ºF and put the upper triple in for 7 minutes to heat up.

The triple was about 430 degrees or so when I took it out of the oven and the screws came out with relative ease at that point with a flathead screwdriver

 

[Windsor1]

I also used an angle grinder to chop off the remaining stubs.