Front Sprocket Cover Bolt Won't Come Off

z0sum · February 15th, 2017, 04:24 PM

I needed to take off my front sprocket cover for changing my sprockets and chain. The first two bolts turned fine, got the the third and it kept spinning on the bolt. The socket size was the same, but the edges of the third bolt seemed very rounded. It's weird because I've never opened these screws before. Anyway, anyone got any advice on how to get it this thing off? It's in such a tight spot as well so that makes me way more of a pain.

Here's a picture if it helps of which screw I'm talking about. It's the top left screw on the sprocket cover.

I tried WD-40, using a nose pliers and spinning from the front, nothing. The area is so cramped.

Triple Jim · February 15th, 2017, 05:53 PM

It might come out if you can get Vise Grips on it. Or use a Dremel tool and thin cutoff wheel to cut a screwdriver slot in it. Or grind the entire head off with a Dremel tool, remove the cover, use Vise Grips to remove what's left of the bolt, and replace it. Or if you're handy with welding, weld a bolt to the head. Sometimes you can luck out and find a socket that's just a little too tight to go on, like an English size, tap it on with a hammer, and use it to unscrew the bolt.

jrshooter · February 15th, 2017, 08:15 PM

everything tripple jim said, if you got a welder just weld the bolt on and be done, if not, a ez out.

Motofool · February 15th, 2017, 08:20 PM

One of these may do the trick:
http://www.harborfreight.com/9-pc-38...set-67894.html

Additional option:
In order to protect the cover from any damage in the process, I would drill as close to the center of the head as possible, until making the head weak enough to break loose; then, remove the stem with vise-grips.

MLR · February 16th, 2017, 02:28 AM

Spray with WD40 in behind the cover where the thread is, also give it a few good hard hits before and after spraying then leave it for a day to let the penetrant do its thing.

Next day give it another couple of hits then try to knock on a slightly smaller socket and see how you go.

A impact driver may help.

If all else fails I would use a easy out, I would still use the WD40 and hit the head a few times.

Rounded bolts are arse.

February 15th, 2017, 04:24 PM	#1
z0sum ninjette.org member Name: Breh Location: Texas Join Date: May 2012 Motorcycle(s): 2008 Kawasaki Ninja 250R Posts: 38	Front Sprocket Cover Bolt Won't Come Off I needed to take off my front sprocket cover for changing my sprockets and chain. The first two bolts turned fine, got the the third and it kept spinning on the bolt. The socket size was the same, but the edges of the third bolt seemed very rounded. It's weird because I've never opened these screws before. Anyway, anyone got any advice on how to get it this thing off? It's in such a tight spot as well so that makes me way more of a pain. Here's a picture if it helps of which screw I'm talking about. It's the top left screw on the sprocket cover. I tried WD-40, using a nose pliers and spinning from the front, nothing. The area is so cramped.

February 15th, 2017, 05:53 PM	#2
Triple Jim Guy Who Enjoys Riding Name: Jim Location: North Carolina Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot. MOTM - Oct '18, Aug '17, Aug '16	It might come out if you can get Vise Grips on it. Or use a Dremel tool and thin cutoff wheel to cut a screwdriver slot in it. Or grind the entire head off with a Dremel tool, remove the cover, use Vise Grips to remove what's left of the bolt, and replace it. Or if you're handy with welding, weld a bolt to the head. Sometimes you can luck out and find a socket that's just a little too tight to go on, like an English size, tap it on with a hammer, and use it to unscrew the bolt.
	1 out of 1 members found this post helpful.

February 15th, 2017, 08:20 PM	#4
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	One of these may do the trick: http://www.harborfreight.com/9-pc-38...set-67894.html Additional option: In order to protect the cover from any damage in the process, I would drill as close to the center of the head as possible, until making the head weak enough to break loose; then, remove the stem with vise-grips. __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

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February 15th, 2017, 08:15 PM	#3
jrshooter ninjette.org guru Name: john Location: placerville Join Date: Apr 2016 Motorcycle(s): ninja 300 Posts: 386	everything tripple jim said, if you got a welder just weld the bolt on and be done, if not, a ez out.

February 16th, 2017, 02:28 AM	#5
MLR ninjette.org member Name: Mark Location: Australia Join Date: Feb 2017 Motorcycle(s): 2011 Ninja 250R Posts: 219	Spray with WD40 in behind the cover where the thread is, also give it a few good hard hits before and after spraying then leave it for a day to let the penetrant do its thing. Next day give it another couple of hits then try to knock on a slightly smaller socket and see how you go. A impact driver may help. If all else fails I would use a easy out, I would still use the WD40 and hit the head a few times. Rounded bolts are arse.