2001 k1200lt banjo bolt removal

[kinterridge]

I have a new to me K1200LT, less than a month, 3rd owner. I've going through all service, all fluids, brakes, etc. Changing out the brake hoses w/ stainless, the banjo bolt up at the bracket where the 4 lines come together has the hex 's stripped out by either the original owner or one of the shops he used, I have all service records since purchased new. I am going to make the assumption I need to remove the block off the bike to remove it, unless some one has a better solution. Let me know, thanks.
k1200lt banjbolt.jpg

[Omega Man]

How about filling a couple of flats on opposite sides and grabbing it with a pair of vice-grips?
Or- take a small chisel with a good edge and tap it around……using multiple tap locations.
A bit of penetrating oil like WD-40 certainly won’t hurt.

OM

[kinterridge]

I would use the file but I am sure I can't get but one side, its tight up in there. I have hit it with 50/50 atf and acetone, I have female thread extractors, if I can get a good bite maybe..., I'm avoiding removing more tupperware than needed. Thanks for your thoughts.

[20774]

If you can get a good heat source close to things, applying focused heat on the bolt heat and then putting more ATF/Acetone on as it cools will help draw the penetrant in. Time is your friend in these situations.

[kinterridge]

Good idea Kurt, I still have all my old lead working irons, I think I've got one that would work nicely up in there. I'll give it try if it doesn't come loose when I get home tonight, Thanks.

[kbasa]

Get the next size up allen and bash it into the hole. I've done it. It's crude, but effective. Allens are fine, but if you can bash a Torx bit in there that's slightly larger, it's going to get you better purchase to get that thing out.

I'd also be applying PB Blaster like it was holy water and that thing was possessed, no matter the methodology. You only need to get it started, so once you've broken it free, the rest ought to be easy.

I also wouldn't be above grabbing it with a big ol' pair of ChannelLocks and twisting it out. That fastener is all done, so go medieval on it.

[kinterridge]

I was able to remove the junction bracket up inside and removed the banjo bolt with a 4" Stillson wrench. All good. Thanks for the input.