I couldn't get to the nut on the bottom, there's a plate on the inside of the rear fender that covers it. I went to advance and got a set of reverse direction drill bit screw extractors. Pre-drilled the hole using a normal bit then switched to the extractor and went slow. Of course this was followed with a second trip to advance since I now had the offending bolt out and could match the thread size for a replacement.

All is well now. There is a 10mm bolt, which is the same size as the other 2 seat bolts so I'm happy. Btw, I don't think I could've taken the filter cover off w/o taking the seat off. There's a philips screw on the top edge of the cover that is impossible to get to w/o taking the seat off.

IIRC, the 4 mm allen wrench is what fits that rear fender seat bolt.
Remember, antisieze is your friend.
If the head of the bolt distorts & the allenwrench doesnt want to play, take a small punch &( while protecting the paint from a runaway tool) give that little bolt a few sharp cracks.HARD isnt as necessary as sharp, quick taps, just trying to create some vibes between threads & unstick it. Getting a penetrating oil into that darned thing isnt easy, but maybe you could rap it, try it, if no good, dose it & try rapping it again next day.
If a head on a screw distorts, odds of winning drop, but I have used a pin punch, moved metal back into position & won, several times.Usually on phillips stuff.Dont recall it on an allen, but its worth sharing.

I got rid of the hex head bolts under the sides of the seat. 2 long allens, with jam nuts, now an allen wrench pulls the seat up there too.

justin_o_guy2 wrote on 03/22/09 at 10:45:10:


Spray penetrating oil on it, lay an ice bag on the fender ensuring it touches the bolt head well and let it sit for 2 hours.  Then do the sharp tap and try it.  The ice will make the bolt and bolthole contract in size just a wee bit.  Combined with the oil and the sharp tap it's the best chance you've got.  

Two ways to remove that rascal.
The crude one is to stick an allen of the closest size in it and arc weld around it. Then unscrew it and throw it away.
The other is to drill down through the allen hole with the same size drill as the bolt thread. Drill only far enough to remove the button head. With the seat removed there should remain enough to get hold with pliers and remove the rest. Without the compression strain of the head, the bolt should unscrew easily.
Then get another butt head screw to replace it.

aliassmith

  Yep I remember that phase well