You might think this is overkill, but the two hex button screws on the kickplate on the exhaust on my V100 have seized solid. Hexes look as if they’re going to strip if given any welly.
I’m thinking of getting 2
cheap torx bits, hammering 'em in and then applying a blob of weld, which will apply heat locally and give a secure joint so that the screws can be wound out.
However, as the weld will be applied via a stick welder, is this likely to fry the ECU?
Your thoughts would be appreciated.
If this is a new V100 why not take it back to the garage to sort it out?
Alternatively can you remove the exhaust and deal with it off the bike? Heat is always very good for removing stuck bolts. Can you heat the assembly with a hot air gun before trying to undo the 2 bolts?
A long story.
Basically, the bike has now been back to the vendor for a new exhaust hanger bolt on two occasions to be replaced under warranty (this is the bolt that suspends the cat box - a known weak point on this model).
When the bike came back from the latest replacement, that plate on the exhaust was badly scratched, presumably when the shop had extracted the two screws that secure the exhaust bracket to the rear of the crankcase, using a wobbly socket extension.
Now this bike has been back to the dealers in question a number of times for warranty work (including a replacement engine at 2300 miles) . This time, and this time alone, I received a “health check” video, purportedly taken when the bike was received at the workshop.
On close examination of this video, the scratches are clearly visible. The shop is claiming that the scratches were there when they picked the bike up.
As I had washed it before it was collected, I know they were not.
Anyway, it was when I was attempting to remove the kickplate that I found the screws holding it on were seized.
So the shop has just bodged the repair with a big FU to me.
Anyway that plate is going to have to come off one way or another, so that I can repair the scratches.
I have this on my Stelvio. The left hand kick plate screw fell out and the right hand one is stuck solid, now with a rounded hex socket in it (my bad). Suggest all owners try to loosen clean and retighten theirs.
Presumably these bolts get hot when the bike has been running, try and release them when they are hot as the expansion might just help a bit.
I would be very wary about using a stick welder on the bike. If you do resort to welding then remove the exhaust from the bike first.
Yep. One of my heat shield bolts fell out - I replaced both with M6 x 10mm hex head.
Hi Don
Agree. I will try my MAPP torch on them first…I just thought the blob of weld trick would be less hassle, but I’m sure that I’ve heard of people cooking their ECUs with “on-bike” welding tricks.
Caution will prevail.
Once you get them out, replace with stainless bolts and add some coppaslip to the threads.
That sounds like a bike dealer to avoid.!
I’m no expert, but I’d defo look to unplug any vulnerable (and expensive) bits of lectrickery before winding up an electric weld set…
Are you able to drill it out, with care I’ve done exhaust studs in the past.
Or maybe grind the head off.? Again with a good deal of care, then dispatch what’s left behind.
As suggested, it seems a liberal application of suitable grease is needed on so many exposed parts these days, I guess that’s a result of cost-cutting and the widespread use of cheaper fittings.
Good luck 
