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2002 Suzuki Vinson Rear Rotor #5130621 06/10/19 06:32 PM
Joined: Aug 2012
Posts: 505
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Recalculating Offline OP
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Joined: Aug 2012
Posts: 505
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?

25FD9094-BE6E-499D-A1BB-9072F053D929.jpeg372DF11C-1F46-4D8B-B32E-33889BBD0598.jpegEFFC2DC5-AD36-4A13-B5B8-5F5E84FABB2B.jpeg

2009 Honda CR-V EX-L 59k
2007 Buick Lacrosse 59k
2008 Ford Ranger XLT V-6 4.0 SOHC 75k
Re: 2002 Suzuki Vinson Rear Rotor [Re: Recalculating] #5130711 06/10/19 07:44 PM
Joined: Apr 2018
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Imp4 Online Content
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Posts: 1,087
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...


2001 Mitsubishi Galant 2.4 - 165k+
Grandma's creampuff...
Re: 2002 Suzuki Vinson Rear Rotor [Re: Recalculating] #5130725 06/10/19 07:56 PM
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Saul Offline
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Posts: 171
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

Last edited by Saul; 06/10/19 07:59 PM.
Re: 2002 Suzuki Vinson Rear Rotor [Re: Recalculating] #5130807 06/10/19 08:57 PM
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Posts: 66
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racinjason Offline
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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.

Re: 2002 Suzuki Vinson Rear Rotor [Re: Recalculating] #5131759 06/11/19 09:00 PM
Joined: Aug 2012
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Recalculating Offline OP
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No welding so I will drill the flat head off the four and tackle the leftover stubs.

Thanks for the suggestions BITOG.


2009 Honda CR-V EX-L 59k
2007 Buick Lacrosse 59k
2008 Ford Ranger XLT V-6 4.0 SOHC 75k
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