help with a small motor issue

[jokofish]

Yamaha 200 4 stroke: I have a smallish bolt with a hex head that holds my apron together. The hex head has gotten stripped. Can anyone recommend an easy/best way to remove this so I can replace the bolt? see attached pic

[adrenaline]

Maybe the next size larger allen wrench with the tips tapered will work?

[Don G Baldi]

Hardware store with a decent tool selection. There is a type of socket with round pins instead of a 'hole'. When pushed down on the nut the pins will fill the opening in the hex head and allows the socket to get a grip on the stripped out flanges. It also works on regular stripped nut and bolt heads. Don't know the name of the thing.

[gettin' fishy]

A pair of vice grips and grab the edge.

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[jokofish]

Originally Posted by gettin' fishy

A pair of vice grips and grab the edge.

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the head is tapered and so can not be grabbbed with a vice grip also it is in a tight spot down in a depression..

[Pensacola]

Google "Easy Out" or "Screw Out" stripped screw removers. I believe Home Depot carries them. Good Luck and let us know how you fare please.

[gettin' fishy]

Originally Posted by Pensacola

Google "Easy Out" or "Screw Out" stripped screw removers. I believe Home Depot carries them. Good Luck and let us know how you fare please.

This∆

I have cut a slot in bolt heads before with a Dremel and used a screw driver. Not sure if you have the room to do that



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[jokofish]

Originally Posted by Pensacola

Google "Easy Out" or "Screw Out" stripped screw removers. I believe Home Depot carries them. Good Luck and let us know how you fare please.

Thanks will do

[Chukarhead]

Originally Posted by Pensacola

Google "Easy Out" or "Screw Out" stripped screw removers. I believe Home Depot carries them. Good Luck and let us know how you fare please.

x3. Hopefully the bolt head is small enough for a basic drill-mounted extractor bit. Do your best to loosen it up with penetrating oil and a few raps with a hammer before using the extractor. If you strip it out larger than your biggest extractor, you'll need to drill down into the shank, which can be touch-and-go. Good luck!

[jokofish]

And now an online search shows me that the Yamaha bolt/collar/washer/nut kit is like $50.. Great

[Dave G]

Easy out for sure. BUT be careful, drill a large enough hole so you can get a good size easy out in there. If you just go with the smallest easy out and it snaps, then you are really screwed.

[bolen05]

Weld a bolt on the end and use the head of the new bolt

[duece]

I have good luck using a torx bit tapped into place for some of those culprits.


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[flatman]

you can also epoxy an allen wrench in there that fits a little loose. then after it fully cures you can turn it out unless it is frozen in there then you will not get it this way.

[Fishndiver]

Originally Posted by duece

I have good luck using a torx bit tapped into place for some of those culprits.


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^^^this. The bolt is probably stainless so drilling it will suck. It’s probably threaded into aluminum so if your drilling isn’t perfectly straight, that will also suck. I’ve actually had great luck using a torx bit tapped into the heads of stripped out Allen heads like that. The torx will bite and the tapping gives a physical shock to help loosen the threads. You could also try external extractors. I have a couple sets to cover different size fasteners and they have saved me a number of times when “up in the brush” working on equipment and things go south. They are worth their weight in gold when they work. I don’t have a welder on my service truck so that is never an option for me. I’ve done well without it anyway. You can find a decent set of extractors, both internal and external and the corresponding sized left handed drill bits on the internet.

[Crazy Outdoors]

Not common house hold tools but manual impact wrench.
take bit from next size up (std or mm) hammer in and then use impact wrench. done that a few times.

[adrenaline]

Originally Posted by flatman

you can also epoxy an allen wrench in there that fits a little loose. then after it fully cures you can turn it out unless it is frozen in there then you will not get it this way.

This is good advice, this has worked for me in the past, so has the taper the end of a larger size allen wrench.
Easy outs don't work well on hex holes, you may have to drill the opening first, regardless, I would try other methods first, every DIY mechanic should have a set or 2 of easy outs, I have 3 different types, if all else fails you may have to completely drill it out, than pliers or vise grips to remove the screw. $50 for a bolt, & washer?, man that's tough to take, I'd go to the hardware store for a much cheaper alternative.

[adrenaline]

Originally Posted by Fishndiver

^^^this. The bolt is probably stainless so drilling it will suck. It’s probably threaded into aluminum so if your drilling isn’t perfectly straight, that will also suck. I’ve actually had great luck using a torx bit tapped into the heads of stripped out Allen heads like that. The torx will bite and the tapping gives a physical shock to help loosen the threads. You could also try external extractors. I have a couple sets to cover different size fasteners and they have saved me a number of times when “up in the brush” working on equipment and things go south. They are worth their weight in gold when they work. I don’t have a welder on my service truck so that is never an option for me. I’ve done well without it anyway. You can find a decent set of extractors, both internal and external and the corresponding sized left handed drill bits on the internet.

True, drilling out is a pain, & a last resort, but he only needs to drill out the head, if needed. Yep a torx bit might do the trick.

[Pensacola]

Originally Posted by jokofish

And now an online search shows me that the Yamaha bolt/collar/washer/nut kit is like $50.. Great

Harbor Freight Tools

Warrior Screw Extractor $7.95

KISS Principle applies here!

[Threeweight]

Go to Harbor Fright and spend $10 on a torx bit set. These are tapered star shaped bits, used on a lot of European cars. Look like this:

https://shop.harborfreight.com/media...mage_24992.jpg

Pick a bit just slightly larger than the hex head opening, attach it to a 1/4 ratchet extension, and gently tap it into the head of the bolt with a hammer. Then attach your ratchet handle and unscrew the bolt.

Then take the bolt with the stripped head down to your nearest Tacoma Screw/Parkrose Hardware/Fastenal/etc..., and buy a marine-grade stainless hex head in the same size for $2 and call it good. Treat the threads with good marine grease before inserting.

And never, ever use a SAE allen wrench to try and remove metric hex heads on your motor ever again

[jokofish]

ok thanks for all of the great options I will try the torx bit set and see what happens -

[tfonev]

I think the torx-impact driver is the best idea of the bunch

[weld22]

Originally Posted by duece

I have good luck using a torx bit tapped into place for some of those culprits.


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This. Works great on stripped allens on old Ford front locking hubs.

[NancyAnn]

I've got the same engine but have not had one strip. My best guess is smaller needle nose vice grips. JB

[Barviewrocks]

Joch, I have a 1/2 inch impact electric if you want.

Jeff

[jokofish]

Originally Posted by Barviewrocks

Joch, I have a 1/2 inch impact electric if you want.

Jeff

I got the bolt out with a screw extractor set last night. Thank you very much for the offer I appreciate it

And thanks to all for all of the great suggestions the folks on this forum are one handy bunch. What a great resource!