2002 Suzuki Vinson Rear Rotor

[Recalculating]

This ATV has near 2000 miles on it. Good running.

I have purchased a new rotor, pads and replacement bolts.

As shown in the photos, the hex mounting bolts have been rounded off and are solidly corroded in place.

Is the only answer to remove the rounded off bolts is grinding the heads off and what remains use locking pliers, penetrating oil and heat?

 

[Imp4]

Flat head cap screws are typically easy to drill out because the head is so low profile.
I just use a drill bit equal to the screw major diameter and it's easy to pop the head off.
Then some PB Blaster and a beer break.
Follow up with some vise grips and it usually loosens.

Otherwise, drill the whole bolt out using a drill bit 1/64" under the tap drill size and run a tap down the threads.
Things can get dicey if your drill walks off center...

 

[Saul]

I would use stubby easy out first, hammer a close size in, no drilling. If that doesn't work then I would take the head off. If the shank won't come out with the head off I would then easy out that.

This or similar. There are also chinese kits if this is a one time use tool.
https://www.amazon.com/Irwin-Tools-...mp;psc=1&refRID=WNBJFXDX1NEFV191DKQT

 

[racinjason]

Weld a nut to them. If you can, drive it down then weld it. Heat will help loosen it up also.

If you don't have a welder, get the drill out.

 

[Recalculating]

No welding so I will drill the flat head off the four and tackle the leftover stubs.

Thanks for the suggestions BITOG.