Maybe, try to drill the head of the bolt off. I have done this a few time, but have not had to on my bike. Just drill a pilot hole in the center of the bolt a little deeper than the thickness of the bolt head. Then move to a larger drill bit. Repeat until the hole gets large enough and the bolt head will come off, from the stud of the bolt.Then you can remove the strut cover, spray with WD 40 then grab the remaining stud with some vice grips to remove. Go slow patience is required. Good Luck!

 

Go to a Sears and get an easy out set. Just ask the tool guy and he'll hook you up.

 

Since I work on Helicopters we have this problem ALOT with screws and bollts.... One trick is like one post said take a file and file a straight slot into the head for a #2 or #3 Flathead screwdriver. This sometimes works but depending on how good ur screwdriver is...I've broken quite a few SnapOns at work. Also, there is this compound that we call easyout (can't remember technical name) but essentially it's just a tacky gel-like substance with grit in it. Put osme in the hole and then it fills the hole to where ur Torx head will fit and grab. An easy trick to that instead of buying some is to just spit on the torx head and put it in the dirt to coat it good. Works just as well. Also, an actual bolt-out or screw-out kit works really well. They are better than the old Easy-out kit. Hope this helps. Like one guy said, you could drill off the head but I'd try these things first since soemtimes it's a pain in the *** using the vice-grip trick. You might not have enough to grip since you said you didn't even budge the bolt. I've done that one before too!

 

Well, luckily for me my bolt came half way out and then stripped, so I was going to try the vice grips first. That white stuff harley put on there is a pain in the *** to remove. I just haven't tried it because I don't have the replacement bolts yet, so I didn't want to go ****ing with it yet.

I will definately keep your hints in mind and go get me an eazy out kit soon! I see me needing it pretty often!

 

Dude, I completely forgot about that trick! You can use Comet cleaner as well, just wet it a bit to make a paste and pack the bolt head. Works just as well.

 

I had the same thing happen with the Autozone torx bits. They're junk! I went to Sears and bought a set of Craftsmans. Even tho the bolts seemed stripped, the Craftsmans pulled them out no problem . Good luck!

 

make sure you run a tap through the threaded holes again before fitting bolts back into them

 

Phrogman...I forgot about that as well. I think it sometimes works better. Essentially it's all the same concept.