Rounded bolts!!

[Fletch89]

A bolt on the alternator housing has completely ceased and now is completely rounded Kept spraying with WD40 but its flanged so it's doing bugger all. Any suggestions?

Thanks

[Wicky]

Presume it isn't the centre hex cap bolt but the retainer bolts around the outside.

File one side of the rounded bolt head flat using a metal file, then file the opposite side flat to you have two parallel flat sides that you can use an adjustable spanner on. If you can somehow make a mask out of heat resistant material to leave just the rounded bolt head exposed while protecting the alternator cover surface/paint and apply some heat from a blowtorch.

Or saw across the bolt head with a hacksaw and then use flat head in an impact driver.

Failing that centre punch a guide mark in the bolt head centre, use increasing drill sizes to remove the offending bolt head. The when the cover is off remove the remaining protruding screw stud with some mole grips.

Afterwards might then be an idea to replace all the Storm's bolts with stainless steel allen heads and some copper grease.

Have fun and post some pics!

[tony.mon]

Sorry to disagree, Wicky, but there's no point heating up the bolt head when the stuck bit is likely to be the thread end. No proper heat will travel down the bolt to the engine casting.
Although you could just warm the bike up to operating temp; that might help a bit?

If it's the head end that's stuck, just tap it one way sideways and then the other to free it off, then try the methods as below.
The bolt is a clearance fit through the alternator casing, and so can move a little side to side.