I'm installing new headlight brackets that slide on over the fork tubes. I'm trying to remove the top fork support bar so I can slide these things on. Assuming I'm targeting the correct bolts, they are not budging. Save me, oh K bike brothers.



I've tried uploading this photo a bajillion times and it always uploads rotated wrong. Same thing with photos I tried posting yesterday. 

First thing, get your bike off its side   

Get a bottle of Marv. Mystery Oil and a can of acetone. Mix 50/50. Apply it to the bolts and leave it, overnight if possible. The best penetrating oil you can get. 

And gawd do not make a hash out of the bolt hex. It's easy to do and hell to rectify. Aluminum can, does 'weld' to other metals given time and conditions. This could be what you're dealing with.

Sometimes, giving a good blow with a hammer on the head of the screw will help "unseizing" the thread.
After that it will be easier for the penetrating oil to clear the corrosion.

CF

Ordered the penetrating oils and will give it a go. I was definitely afraid of stripping this thing out, that's why I came to y'all.

CF, Ah! Yes! I've used this trick before. I'll give it a shot along with the penetrating oil.

Get a small asbestos mat from a plumbers' merchant to shield the wires and cables and get some heat on that sucker.

When you do get it out make sure it is replaced by a socket head screw of normal depth.  For some crazy reason these bolts have a shallow head for the Allen key to locate into.  Couple that with their tendency to seize and you have a problem.

I applied the penetrating oil/acetone mix with no success. I just applied it with a rag and let it sit most of the day. Is there any trick to applying it?

Last resort is getting my torch out.

I know that this is a last resort thing but peining the alloy around the bolt with a 12oz ball pein hammer can make the corrosion let go as well it also makes the surface dimpled but I reckon that at this stage getting the bolt out is the aim.
I have a set of old allen keys that are now just a straight shaft and a set of small ring spanners that fit each size down to 5mm (stahlwille) and put the key in the head of the bolt with the ring spanner on the key then pound the end of the key and apply some pressure to undo at the same time. Don't be afraid to pound it hard as the only thing that you will damage is the old allen key and they are plentiful.

When you do manage to remove it, replace both upper and lower ones with hex bolts. You will need a couple of additional washers on the lower bolts to enable the hexagon to clear the counter sunk holes. Don't forget to lube them! John

After pumping some iron, I was finally able to get those buggers off. Turns out that the penetrating oil mixed with some bigger tools did the trick.   

xpc316e wrote:Get a small asbestos mat from a plumbers' merchant to shield the wires and cables and get some heat on that sucker.

When you do get it out make sure it is replaced by a socket head screw of normal depth.  For some crazy reason these bolts have a shallow head for the Allen key to locate into.  Couple that with their tendency to seize and you have a problem.

Asbestos Mat? You still can buy those?