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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
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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.
 

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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.
 

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1998 R1
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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 .
 

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2012 YZF - R1
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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.
 

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'08 R1
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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.

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Discussion Starter · #13 ·
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

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