Front tank cover advice please

[paulo]

2012 650 - I'm struggling to remove one of the front tank cover securing allen head bolts. Do you think it would be OK/safe to use a mini torch to heat it up bearing in mind it's location, the thread is on a tab welded to the tank. I've had success with this method to remove front mudguard bolts. Assuming I do manage to remove it, does anyone know the part number of the bolt. I've found a diagram on the MSP site, but it doesn't show the bolt. I only wanted to raise the tank for a coolant top up!

[Fat Rat]

Is it rounding off? I have cut a slot in these before and removed with a flat blade screwdriver.

[Fat Rat]

This should help with the part https://www.fowlersparts.co.uk/parts/5544729/DL650-l2-l5-2012-2015/fuel-tank-cover (09139-06178)

[Rusty Nuts]

If the socket is a bit goosed, try tapping a slightly over sized torx bit in, then replace the screw later.

[Gert]

Do NOT use a torch / any flame, to heat up any metal fasteners that secure the tupperware on your ride. If you need to heat up the metal fastener, rather make use of a hot soldering iron. Keep in mind of the damage that excessive heat may cause to the tupperware.
A torx bit, as suggested by Rusty Nuts, has helped me in the past. Expect some slight damage to the torx bit and you will need a new fastener.

[Loopian]

I had exactly the same the other day on my new to me glee, I soaked in plus gas, masked, covered up the tank and CAREFULLY used a dremel to cut a slot in the mushroom head, and using  a flat screwdriver it undid easily. I’ve now used copper slip on the new and associated fasteners.  I did try a torx bit but couldn’t get one to bite properly.   Good luck
Ian

[tallpaul]

Hammer and centre punch is my normal method for fecked up button head screws that have reached the point of last resort. Punch a dimple at the edge of the screw head,  then use the punch in the dimple to tap it round anti clockwise.

[paulo]

Thanks for all your suggestions. Have tried plusgas/Wd40 - failed. Have tried using a torx head - failed, have tried using a centre punch and toffee hammer - failed, will have to try a dremel I guess, but there isn't much of the bolt head showing above the recess in the cover, or drilling it out as last resort. Thanks for the parts diagram, but it doesn't show the bolt unless I'm mistaken. Has anyone got the part number or did you buy from a DIY store etc

[Loopian]

This is the part number 09139-06051, l got mine from Fowler’s. The size is 6mm x 10mm.
Ian

[Joe Rocket]

Can I suggest a gentle try with an impact driver when you have a good fitting blade/allen/torx?

Even on an 8-y-o bike the thread cannot be immovable with the right driving force.

[paulo]

Thanks for all your suggestions and part number. I don't think I'll be able to prep it well enough to use an impact driver, so will order replacement bolt and soldier on with it. Stay safe and well.

[Ianmc]

Is there a reason that you cannot just drill the head off, remove the plastic and then use molegrips on the stump ? Or am I missing something somewhere ?
Just take your time and make sure that it doesn’t get too hot.A piece of rag soaked in cold water will help.

[Gert]

Perhaps you can post a good close-up pix of the fairing screw, that is causing these headaches? Not understanding why the fastener won't screw loose, after trying either / any / all of the suggestions above.

[The Doctor 46]

Explosives! Have you tried to blow it off?

[kwackboy]

A Bit Harsh .. 

[hotbulb]

Quick, though!

[tallpaul]

Entertaining for the neighbours too...

[hotbulb]

Every cloud.............. 🙄

[paulo]

Using explosives sounds like a dynamite and fun idea. Boringly, careful use of a small cutter to groove the bolt a and flat blade did the trick. Sorry to disappoint! Thanks all