Stuck Valve Cover Bolts!

What do you think guys? These things haven't been out since a Japanese supervisor said, "Ok...let's get these valve cover bolts in and the bike on the boat." Any suggestions?

 

penetrating oil and a looonggg allen wrench or a ratchet with the allen head tip.

 

x2 on the penetrating oil + long socket. Also, A little heat (torch) never hurts.

 

I'm on my way to the auto parts store now for penetrating oil!

 

Kroil is a popular penetrating fluid use by alot of fellow KJer's on here.

 

This is a perfect example for why I recommend having some "Special Tooling" for working on your XJ-Bike.

Allen Head "Socket-set"
Craftsman 3/8th Inch Drive Ratchet Handle
Oak or Hickory 20oz. Framing Hammer Handle
(Remove the cut and split which enters the Hammer Head)

Using the Allen Socket and Ratchet Handle ... apply very firm Undo Torque to the Cam Cover Fastener.
Then, ...
Using the Hammer Handle ...
Strike the Ratchet Handle very sharply.

 

I gotta agree with ricks hammer handle. Ive used it several different ways while working on my bike since I read it from him a while back...def great item to have.

 

also heating up the bolt and touching around the area that makes contact with the bolt with a crayon or similar wax object draws the wax into the thread to aid in removal. ive used this trick to free stuck intake bolts on cars before.

 

These are all great ideas! I can't believe there isn't a thread devoted to stuck valve cover bolts yet. I bet there will be lot's more now that Fitz posted a valve clearance how-to!

 

you can put all the penetrating oil and wax in the world on them but the bolts have rubber washers under them to keep the oil in the engine and all that other stuff out
go someplace and get a hand impact driver
http://www.harborfreight.com/cpi/ctaf/d ... mber=93481
and a set of good bits

 

It's funny you say that Polock because last night I went to Sears to get one and they had no idea what I was talking about! Apparently they don't sell the "hand" impact drivers.

 

I Just did mine adn was surprised how tight the Dang things were. (for only being 7.2 lbs of torque!!!) Place allen key in, make sure it's in good!... Now grab a 12mm or 1/2 inche box wrench, slide it in over the allen key end, jus tenough to grab it and give you leverage. Now with out slipping, give it a good crank backwards. It should go Crack.. good crack not bad crack. Do this to each one just to free them, then remove.

Now as for the bolts, how much of a bugger is it to change the Ruber washer on them? Mainly the centre ones. Have one that I think is drbbling some oil up through it? And think this was the one bugger One I had an issue getting out of the Pan/Cover.

 

I am lucky enough to have air impact tools (cheapy ones, certainly would like to have better) but I also picked up a hand impact driver from ACE hardware for around $20. Not a bad price if you don't have a Harbor Freight in your neighborhood and can't wait for mail order. I prefer to use the manual one most of the time if I have enough room to swing a ballpein hammer.

Palmer, you are absolutely right about Sears not having the impact drivers. The salesman just got this glazed over deer in the headlights look when I asked about one. Didn't have a clue what I was looking for. Harrumph said I under my breath, Obviously never worked on an old metric motorcycle. No grease under his fingernails either. Another dead giveaway!

I picked up a Craftsman metric allen head socket set a few weeks ago for less than $20. Again, so I can use an in/lb torque wrench to tighten those little fasteners down "oh so just right".

 

The best way is to get medieval with the old ones and cut/hack/destroy them off.

Then apply a dab of silicone grease and muscle the new ones past the shoulders. Much easier since the new ones aren't hard as rocks like the old ones.

 

Should I destroy the old rubber washers on the inner-most bolts so I can get some penetrating oil on em? I don't want to take any chances with breaking these bolts off. They're very tight!!!

Oh and BTW...did you know that Kmart sells Craftsman tools? I noticed the hand impact driver was there for 5 bucks cheaper than Sears.

 

After a good nights soak in PB penetrating oil, I was able to crack all 6 valve-cover bolts loose! Of course with the aid of a two-foot pipe, which when placed over the end of an allen wrench gives you some much needed leverage. Thank God that none of the bolts broke off in the head.

Now...the IGNITION COVER SCREWS!!! - On the other hand - Should have waited til I got myself an impact driver! Three out of four broke loose with a long screw driver affixed with a pipe wrench for added torque. One screw was so stripped out by the previous owner, I had to cut a notch in it with a hacksaw, heat it up and break it loose with channel locks! Phew!

 

I can only add: http://www.kanolabs.com/google/