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Discussion Starter #1 (Edited)
I'm sure that anybody that has worked on ATV's much at all has had the problem of twisting bolts off in the head or block. For example, on a 350 Rancher, the two small diameter bolts that extend from the head down through the side of the cylinder into the block. They are small diameter, but long in length. Not the 4 main head bolts, but the two small diameter ones on the side. They tend to seize up in the aluminum and twist off when you try to loosen them. I can usually get them out, but sometimes it can be a real pain when they break off even or below even. I know there are a lot of talented guys on here that are good at working on ATV's, so my question is this: Does anybody know any good tricks that make removing these bolts easier. If so, please list your ideals and suggestions in this thread. Something besides using a drill bit and ease-outs, as a lot of the time these just don't work too good. I'm sure it will help a lot of people with this problem.
 

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I have heated bolts up and fed beeswax around the bolt then used a easy out.
 

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Personally if I ring-off a bolt that is above flush one tends to run for the vise-grips. I will take a nut and weld it to the broken bolt that way i can use a wrench. If it's flush or below ? you really don't have alot of choice but to drill and easy-out. If you apply a little heat to the outside of where the bolt is siezed not the bolt it will turn out easier. after I get them out I always retap the hole to clean out the crap that froze up the bolt in the first place. putting uncoated steel in aluminum will cause electrolosis ( ferris and non ferris metals welding together) especially stainless bolts in aluminum. if you see these pretty dress-up kits on ebay RUN!! don't put a stainless bolt into aluminum you will never get it out even with a easyout. and if you snap off an easyout...Heaven forbid you will have to take a punch and pray you can break it out, because you will not drill an easyout. When you get ready to reinstall it PLEASE INVEST IN ANTI-SIEZE!!!!! you will thank me for it later.
 

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an engine builder i know from kart racing showed me to "shock" the bolt... just take a punch of some kind and give a good wack @ the head of the bolt with the punch and hammer... not a whole lot of force but just enough. he said what it does is basically does is vibrates the 'hard' bolt in the 'soft' medal... just a thought and it will unglue the loctite as well in the future which i also suggest using!
 
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