Hmm... axle retainer: 5mm. fork pinch bolts: 3/8". Fork caps: 1 3/8" / 35mm. Front caliper bolts: 10mm / 12pt. I see your point.

Probably easiest would be to drill, and use an ez-out. Didn't craftsman have something that didn't require pre-drilling?

 

Probably do. Problem is, the nearest Sears is just as far from me as the nearest HD stealer. I'll try jamming a torx in there. If that doesn't work, will have to go drilling.

 

If you have a flat awl or flat scribe, you could try inserting it into the recess, and tapping along the sides. Loosening it. I've had to do that on occassion. It does work just a little harder to do.

 

Hammering in a torx was the ticket. Worked like a charm. Thanks WS6 and thanks everyone else for the responses. Now I have a few other questions but I'll start a new thread for those.

 

What size did you use? I'll have to remember that if ever in a bind.

 

Glad you got it out OK. Don't know if you tried any penetrating oil but PB Blaster works wonders to loosen stuck bolts/nuts. Also as a last resort before drilling, weld a regular hex head bolt onto the stuck bolt's head, then use a regular socket to unscrew it.

 

I do have PB blaster and it works great as you said. I bought it and used it when I pulled the stock exhaust on my truck and put a cat-back on. However, these bolts were not stuck at all. I used anti-sieze when I put them in and once I got something in there that would hold in the bolt head, they spun right out. The problem was I couldn't get a bit in there that would hold. I guess I rounded them out when I put them in the last time enough that the bit wouldn't hold.

 

I bought a set of Irwin Bolt extractors a while back. The are meant for regular hex head bolts but have worked great on any allen or torx bolts I could get them on.

 

Here's a photo of the replacement bolts that I used. Another alternative might be using studs and chrome acorn nuts.