Need help removing fender strut plugs

[Magoo]

I have fender strut plugs in my 07 chopper. I need them out for my sissy bar(s). When I put the allen wrench on the bottom of the strut and try to back the bolt out, the whole plug turns with it. I tried to tap it down to make it a tighter fit but no luck. I don't care at this point if I destroy the plugs, just don't want to damage the struts, and save the bolts if possible. Any and all suggestions would be appreciated.

 

[mjsk9]

If I am understanding correctly and they are similar to the 06 K9 plugs, which I believe they are... put the allen wrench back on the bolt / plug from the underneath side and tap it with the hammer until it pops up and you can get a grip on the plug with a vice grip (wrapped in cloth so not to cause damage to the plug / strut) continue to loosen the bolt.

 

[Magoo]

If I am understanding correctly and they are similar to the 06 K9 plugs, which I believe they are... put the allen wrench back on the bolt / plug from the underneath side and tap it with the hammer until it pops up and you can get a grip on the plug with a vice grip (wrapped in cloth so not to cause damage to the plug / strut) continue to loosen the bolt.

Thanks for the advice. Just tried that and it won't come up above the top of the strut. I'm thinking a ez out or a spanner wrench if I drill it from the top?????

 

[mjsk9]

Thanks for the advice. Just tried that and it won't come up above the top of the strut. I'm thinking a ez out or a spanner wrench if I drill it from the top?????

So the bolt has "welded" itself to the plug? Did you try squirting penetrating oil up from the underneath side and let it set for a little while to help break the bond then try loosening? Again on the 06 K9 plugs, there is a little "spur" or "flange" that has a corresponding "slot" in the plug hole and if the plug was not put in that way to marry the two parts, probably when trying to remove, damaged the "spur or flange" and now just lets it spin.

 

[pknowles]

So the bolt has "welded" itself to the plug? Did you try squirting penetrating oil up from the underneath side and let it set for a little while to help break the bond then try loosening? Again on the 06 K9 plugs, there is a little "spur" or "flange" that has a corresponding "slot" in the plug hole and if the plug was not put in that way to marry the two parts, probably when trying to remove, damaged the "spur or flange" and now just lets it spin.

Looks like drilling may be his only optiin at this point. Start small and increase size until the bolt comes out.

 

[woodbutcher]

i know it's getting a lot more involved than you had hoped, but you may have to remove the rear fender and the struts so you can flip them upside down and put penetrating oil in that way.

 

[Mr. Wright]

Those plugs are supposed to have a small dowl pin to keep them from turning. They either broke off, or not on there when installed. Drilling is going to be your only option. Drill from the top, because you may have to use an allen wrench to hold it, to keep it from spinning while drilling.

 

[Magoo]

Those plugs are supposed to have a small dowl pin to keep them from turning. They either broke off, or not on there when installed. Drilling is going to be your only option. Drill from the top, because you may have to use an allen wrench to hold it, to keep it from spinning while drilling.

I think you're right Mr Wright. Penetrating oil will only make them spin easier.

 

[Jersey Big Mike]

Only prayer is penetrating oil and an impact wrench -- You might get enough torque quick enough to break it loose. Put pressure downwards on the top of the plug when you try (not anything that will twist easy -- ie not a towel and your finger!)