SuzukiSavage.com - Can't get seat bolt out

cowspotter

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Can't get seat bolt out
03/21/09 at 13:57:55

So a few weeks ago I installed my new battery and tried getting the seat off but couldn't find an allen wrench to fit the bolt. Managed to get the battery in w/o taking the seat off. I bought a pack of metric and standard allen wrenches because I want to check the air filter. None of them fit.

First of all, what size is that bolt? I have a feeling that the head is screwed up and I'm going to have to get an easy out or something to get that thing out.

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skrapiron -FSO Serious Thumper Offline Instant Human.... Just add coffee.. Posts: 1456 Pittsburgh, Pa Gender:	Re: Can't get seat bolt out Reply #1 - 03/21/09 at 14:14:31 You're talking about an S40, right? My Savage had 10mm hex head bolts securing the seat to the frame. I wasn't aware that Suzuki used hex key bolts for the S40... On my C50, the seat bolts require a 6mm hex wrench to loosen the bolts. If they keep fasteners the same, you might want to try a 6mm 'T' handle wrench.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Can't get seat bolt out Reply #2 - 03/21/09 at 14:48:21 you might try sae sizes. who knows what the PO did.
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Sandy Koocanusa Serious Thumper Offline Don't blame me. I didn't vote for him. Posts: 1878 Bigfork, MT Gender:	Re: Can't get seat bolt out Reply #3 - 03/21/09 at 15:08:05 Yep. Mine had one hex head and one allen head when I got it.
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mick Serious Thumper Alliance Member Offline Hell-bound Posts: 7323 Dayton Oregon Gender:	Re: Can't get seat bolt out Reply #4 - 03/21/09 at 15:13:05 2 hex heads on mine 2002 . I have since changed them to hex heads with a screwdriver slot.
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ALfromN.H. FSO Serious Thumper Alliance Member Offline Dragon Slayer Posts: 1421 Rochester, New Hampshire Gender:	Re: Can't get seat bolt out Reply #5 - 03/21/09 at 15:19:13 My 2005 has hex bolts with screwdriver slots and I swapped those out and now have thumb screws so no tools are needed. AL
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Sandy Koocanusa

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Re: Can't get seat bolt out
Reply #6 - 03/21/09 at 15:32:41

Cowspotter,

When I got my parts bike, the bolts were kind of seized up. They just go through a nut that's tacked to a little tin bracket though. You can wiggle an oil can spout or WD40 nozzle up in there and squirt the back of the nut, allowing the oil to run down the bolt toward the head. That might loosen it enough to let you jerk it out of there.

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Savage: (adj)1. Wild 2. Uncivilized : Primitive 3. Ferocious 4. Cruel or merciless : Brutal --- Webster's. (n.) 1. A motorcycle named for its seat.--- Sandy's unabridged

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cowspotter

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Re: Can't get seat bolt out
Reply #7 - 03/21/09 at 18:20:47

Just thought I would put some pictures up so we are clear what I'm talking about. The bolt might be seized but I'm not even getting to that point. All my wrenches are either too big or barely grab the side so when i turn it, it just spins inside the bolt.

Verslagen, by SAE, do you mean 5/32", 9/64", etc? If so, that's what I tried along with metric.

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SimonTuffGuy

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Re: Can't get seat bolt out
Reply #8 - 03/21/09 at 18:25:48

That bolt is new on the S40 (vs the Savage)... I bought a generic set of allen wrenches and one of them fit. If nothing else works... Use a dremmel and put a slot in, use a regular screwdriver to remove it and then replace it with a normal bolt.

When I removed mine for the first time, it was pretty tight.

FWIW - You should be able to check the air filter without removing the seat. There's a screw on the side (right side if you're sitting on the bike) to get the cover off... And then there's another screw holding the airbox cover on.

Good luck!

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cowspotter Junior Member Offline SuzukiSavage.com Rocks! Posts: 80 Ashburn, VA Gender:	Re: Can't get seat bolt out Reply #9 - 03/21/09 at 18:33:58 I'll have to take a look tomorrow morning. I used to have a dremel.....perhaps its time for another.
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skrapiron -FSO

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Re: Can't get seat bolt out
Reply #10 - 03/21/09 at 18:36:01

It's metric, not SAE. Suzuki does not use SAE fasteners on the bike.

Try a 5 or a 6mm. It looks like someone tried to tighten/loosen the bolt with too small of a wrench and buggered up the inside.

Take a T handle wrench, tap it into the bolt head with a hammer to set it in place, then remove the bolt and order/find a replacement.

I had forgotten that the S40 has a one piece seat now. The Savage had a 2 piece that was secured by bolts into the frame and into the fender.

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WoodLark YaBB Newbies Offline Earth is the insane asylum of the universe! Posts: 34 South Carolina, USA Gender:	Re: Can't get seat bolt out Reply #11 - 03/21/09 at 19:15:38 I'm pretty sure its a 5mm. I did note on my 2006 that a ball end hex key will not grab it properly, but the flat end of the key did work.
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thumperclone

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Re: Can't get seat bolt out
Reply #12 - 03/21/09 at 19:48:17

my 06 came with that same pos screw..i put on a sissy bar and back rest with rack so that forced me to install a new hex head bolt cause the bag on the back rack and sissy bar limits access..
also saddle bags limit access to the two side bolts esp the right side
i use a socket and rachet..
to get em back in a lil elect tape to hold the bolt into the socket helps to get it started..
the 6 way screw driver the came with my cruz toolz set fits the new
bolt i replaced for the back of the seat..
when you go to put it all back together just start the side bolts then the back w/down pressure on the back of the seat...

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verslagen1

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Re: Can't get seat bolt out
Reply #13 - 03/21/09 at 22:19:30

cowspotter wrote on 03/21/09 at 18:20:47:

Verslagen, by SAE, do you mean 5/32", 9/64", etc? If so, that's what I tried along with metric.

Well it was worth a try. If it was SAE, english, fractional, inch, then you would really have a hard time getting it out unless when they put the wrong bolt in they also retapped it.
If all else fails drill it out.
But before that, get a propane torch and heat it up, although I don't like the area in which you are doing it in, plastic melts.
Take a dremel and a cut off wheel and cut a screwdriver slot.

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Savage Eddie Full Member Offline Custom Bob's ROCK! Posts: 204 40 miles west of Chicago Gender:	Re: Can't get seat bolt out Reply #14 - 03/22/09 at 02:06:31 Turbo sockets! heres a ebay link, reverse threded sockets
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