When I have a bolt like that I always tighten first just to break the threads then I try to loosen. I was told that by a mechanic and it seems to work.

 

Bolt has been removed. After unsuccessfully trying a number of suggested techniques I took the bike to a muffler shop. They were not able to get it out either. They offered to weld an allen wrench or nut on it but they were concerned about the weld splatter. They had nothing to protect the surfaces around the area to be welded. I took it to a dealership.

They were able to get it out. I don't know how. They may have drilled it out and then installed a helicoil threaded insert. I don't know because I asked them to install that side adjustable passenger footboard mount kit.

What did they charge me? I have the Diamond Plate Passenger Footboard Insert Kit. Well they took me back to the bike to explain that when they have to remove the passenger footboard the Diamond Plate Passenger Footboard Insert Kit is destroyed because the rubber tips that protrude through the footboard get cut off. They were about to tell me that in addition to the 1 hour labor that I was going to have to buy a new Diamond Plate Passenger Footboard Insert Kit, $84.95. I called BS. I let them know that I had removed the other side and reinstalled it without damage and I had removed the side they were working on 4 or 5 times trying to get the bolt removed without damage and it was still at a point where they should have been able to remove the pins that hold the footboard on without damage. I knew how to do that because I read the installation instructions for the Adjustable Mounts.

Bottom line is the shop rate is $84.95 an hour. I got out for $84.95 + tax.

Thanks for everyones advice.

 

You still need to go buy the set of allen sockets so you don't have this problem againin the future. Proper tools are very important to every job. I've had times I spent more onthe proper tool than the part I was putting on cost. $85 is actually a cheap lesson.
Good luck with further improvementsin the future.

 

Good to hear you got past all that hassle.
Well, now that you've gotten it out, remove it again (and the other footboard bolt on the opposite side) and get some anti-seize compound on it for next time. I have had those bolts in and out a bunch of times and the problem with them is that they are made of a metal that results insome sort of dissimilar metal typereaction takingplace,and they corrode in the female thread where they go. Anti-seize will reduce or eliminate that from happening.
Another place I found it going on was the bolts that secure the ECM module (???)under theright side cover on my RK.( thefinned module that a Power Commander is zip-strapped to. Is that the ECM?)
Go in there an remove those too, and add some anti-seize to them before the day comes you'll be wanting the get them out. When they seize in their little brass holders you 'll mess up the plastic piece the brass nuts reside in. I caught mine just in time and it was inside of 1 1/2 years. You'll be glad you did. I've seen past threads here where others were too late and they came looking for answers.


CN

 

Next time this happens to you shoot me an email or PM and I will do it for you. I am in Plano so should be close by and would do it for free and not tear up your floor boards. Don't take things like that to the dealer.

Jeff

 

I just looked at your profile. Your in DFW. You could have brought it by our Gas Turbine Repair shop.
We can fix ANYTHING