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Discussion Starter #1
Needing a set of new tires for my '12 Nomad my plan was to order the tires, ME888s, take the wheels off and get them to my Indy shop for the new tires install. Did the rear first went fine. The front however has proven to be a real pain due to my lower left side brake caliper bolt that goes though the fork leg and threads into the caliper securing plate won't budge. Tried heat using a heat gun, the cap now is completely rounded off from the 12 mm socket wrench slipping, tried to use a bolt extractor socket no luck. Now I'm really stuck, got my Indy to order a couple of new bolts M 10 X 47 mm but that still leaves the messed up bolt that has to be removed before I can get my front wheel off. What is the best way to get to get this bolt out?
 

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You have some options.

File the sides down until you can get an 11mm 7/16" or even 10 mm socket on it. Grind the tip of the socket flat so that you get more contact area. (A HAND file has one edge without teeth so will not scrape the fork)

Drill and easyout.

Put a larger nut over the bolt head and weld the inside of the nut to the bolt head. Then let it cool and turn it out.
 

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Discussion Starter #3
Thanks Kevin, those all sound like viable methods, I'll post what happens.
 

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I've had luck using "channel locks" (or in my case Knipex water pump pliers) to remove stuck bolts before. They grip harder the harder you push and if you use a larger size it gives good leverage, but they also have the ability to mess the bolt head up right quick so you have to be careful. A liberal spray of penetrating lube could also help, I like PB Blaster. Spray the threads from every angle and side you can, give the bolt a few taps with a hammer and wait. Repeat this a couple times over a few hours and it could help. If the bolt is threaded into aluminum there is a chance that the threads could come out with the bolt, so you may need to use a Helicoil to repair it, hopefully you get lucky though. Good luck!
 

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Discussion Starter #5
Thanks Beans, right now I'm going to hunker down until this weather (snow)passes and my new bolt arrives. Then I'm going to decide whether to let the shop take care of it or ? They have to mount and balance the tire anyway. Whatever happens I'll post what solution turned out to be.
 

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Thanks Beans, right now I'm going to hunker down until this weather (snow)passes and my new bolt arrives. Then I'm going to decide whether to let the shop take care of it or ? They have to mount and balance the tire anyway. Whatever happens I'll post what solution turned out to be.
I was helping a friend change his tires and we ran into the same thing. We tried the bolt extractors and a 3' breaker bar and still no luck. My neighbor is a pretty good mechanic and he couldn't get it to budge. We finally took it to the Kawasaki stealer. I wasn't there, but my friend said they had a bad ass machine that grabbed it and torqued it right out.
 

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Discussion Starter #7
Thanks I figure the deep state has a fix ☺
 

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I use a craftsman cordless 1/2 inch impact wrench to get hard to get out bolts. If necessary I use a bolt extractor socket. Works every time.
 

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Discussion Starter #9 (Edited)
Thanks Bubba, I'm resigned to letting my Indy shop figure it out when the new bolt comes in. I did my last attempt today and the only thing that going to get this bolt out is drill and ez out or drill and tap. My biggest concern is not damaging either the fork leg where the bolt passed through or the brake caliper so it's the white flag on this job. I will post what the final resolution ends up being. Man alive that bolt must be completely seized up.
 

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Discussion Starter #10
Well 1700 Vulcan fellow travelers at long last my front caliper bolt nightmare is finally over. It took a air hammer using a screw bit in the drilled hole that I had started. The guys at Fairfax Cycles jammed the bit into the drilled hole and let the air hammer rip and out the bolt came.
 
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