Removing Ignition Barrel

[schmiffee]

I need to remove my ignition barrel for repair and re-fitting...however upon removal of the top triple-clamp I have found the

Ignition Barrel.jpg

How do I remove these bolts?? I can't see how they would pop out, so I am assuming that they may have to be drilled out...is this correct? Or is there another/better way of doing so??

Thanks, Schmiffee

(Image ammended - was VERY late here and was VERY tired )

[idl1975]

I need to remove my ignition barrel for repair and re-fitting...however upon removal of the top triple-clamp I have found the

following

FZ1-N Headlight '05'..jpg

How do I remove these bolts?? I can't see how they would pop out, so I am assuming that they may have to be drilled out...is this correct? Or is there another/better way of doing so??

Thanks, Schmiffee

You know that's a pic of a headlight right?

Security bolts. Silly, since professional thieves will just pick the bike up and sling it in a van, while amateurs won't get past a disc lock.

Yes, you have to drill them out, or slot the bolts if you can reach 'em and use a screwdriver. Bit of a bugger that.

[Kayla]

If you can, use a left hand drill- seriously. They go in the opposite direction to regular drills and quite often bring the offending bolt out with them- much cleaner and less frustrating than bolt extractors. They do tend be more expensive but they are worth it. When I had to drill mine out I just used a succession of bits from 3 up to 5mm and hammered an oversize torx bit in.

[steve speed]

i just got a screwdriver and gave the edge of the screw a good tap anticlockwize then replaced them with stainless caphead bolts

[idl1975]

i just got a screwdriver and gave the edge of the screw a good tap anticlockwize then replaced them with stainless caphead bolts

Security indeed.

[Kayla]

i just got a screwdriver and gave the edge of the screw a good tap anticlockwize.

That is a classic 'Haynes' type tip right there. Assembly is simply the reverse of disassembly.

[slow codger]

i would guess that they are shear bolts, new bolts have a hexagonal head on them which when tightened to a specific torque snap off leaving the above which can't be undone! As above drill them out.

Dave E

[schmiffee]

I went to my local bike street (Nerang - Lawrence Drive) and tried a few places asking how to remove and basically they didn't want to tell me but were more focussed on telling me that they could do it and it would probably cost a lot of money. Now my question is this - if I do drill them out, how much of the original threaded bit will I have left (basically will I have much metal to work with when getting the top triple-clamp re-tapped/threaded?

[rocket60]

the triple clamp is not threaded I think.after you remove the bolts holding the ignition you will need to replace them with high tensile unbrako bolts and nylock nuts.If your worried about some one removing your ignition you can peen over the bolts after tightening the nuts.

[Kayla]

The top yoke (triple clamp?) is threaded, and you don't destroy any of the thread if you're careful and don't use a bit that's too big. Just start small, and work up to 5 or 6mm, then try (but for a god's sake, don't snap it) a bolt extractor. I managed to do mine ok so it's not that difficult. Have a go, go on, aahhh, go on, you will, go on.

[BennyTRX]

Hi guys - I'm relocating my ignition barrel. Ive found this post.

Am I drilling out the underside or the top side. Ive attached a photo of the bottom side which I have begun drilling out... only to stop and think ah, was I supposed to drill out the top side?

Augh, I'm a muppet having a crack here. Its fun.