2000 GSX600F Stuck Front Valve Cover Bolt

[DGJScout]

Hey guys,

 

New to the forum! Please let me know if I break any rules/don't follow the guidelines to a T. 

 

To the problem at hand, I have a stripped bolt hex bolt in the location closest to the radiator on my 2000 600 Katana.

I have tried using a torx bit, expoxy, and sizing up but I can no longer get a bite. I'll be trying a hex extractor today. It does seem that I may have to use a proper kit, and drill into the bolt though. What would be the best way to access this bolt from the top/side down? I'd like to avoid disassembly as much as possible.

 

Thanks!!

[Upshotknothole]

Your best bet is gonna be to pull the engine to drill it out if it's really stripped. You can try spraying some penetrating oil up into the threads from the underside, the bolt hole goes all the way through, but not really enough room to get a drill in there. I can't remember how much clearance you've got above that bolt with those F frames. If you can get a cutting wheel in there and notch it, you might be able to use a large flat head screw driver on it. If you remove the lower frame support and all but the lower rear engine mount can you rotate the engine down to get better access to it? 

 

[bluedog59]

We're talking about the flat headed allen bolt.  Get a good centre punch and put deep punch mark in the bolt head approximately half way between the socket hole and the edge of the bolt head ( it may require more than one blow ). Now angle the punch at about 45 Deg to strike the side wall of the punch divot to turn the bolt anticlockwise. Now start hammering to undo the bolt.  A little trial and error will soon establish how deep you need to go and what angle but there is enough bolt head and you will need a fresh punch mark as the bolt starts to turn anyway.

Note. Use a Centre punch !!! Not a chisel. Chisels are for cutting and you want to turn it, not cut it.

A little penetrating oil on threads and/or heat on the casting never does any harm.

[Swiss Toni]

Common problem. As bluedog says, use a good sharp punch. Works every time!

[Enjoythesilence]

And get some heat on it too,i have done loads of them in the past in situ.You will have to remove stuff.

Rule broken-Its not a katana

Edited May 16 by Enjoythesilence

[wraith]

I've ended up before now, cutting the head of the bolt off. As they usually seize in the cam cover part.

Then you can remove the cam cover and get the rest of the bolt out.

You will need to remove the engine to do this.

As above, yes I know in the US it's called a kat but it's not a Katana. It's in the site rules  this is oldskoolsuzuki 

Edited May 16 by wraith

[Dezza]

To solve the same problem I have cut a slot in the bolt head with Dremel, then used a fairly large pin-punch and hammer  to rotate it anti-clockwise. I agree with Bluedog in empahasising the need to use a punch rather than any tool designed to cut metal.

And maybe it's time we all get over the arguments over the inter-continental semantic differences in the use of the k word. Does anyone really give a monkeys anymore?

Edited May 16 by Dezza

[DGJScout]

Thanks for all the responses! I’ll get back to you with results soon. (I’ll use better lingo next time I promise)

[DAZ]

On 5/16/2025 at 8:07 PM, Dezza said:

And maybe it's time we all get over the arguments over the inter-continental semantic differences in the use of the k word. Does anyone really give a monkeys anymore?

Not really to be honest mate, especially in the oilcooled section , whilst I love an original Katana (who doesn't !?!) , there's plenty of fake ones about whether they're GSX based or Inazuma,or some other mongrel breed , and Suzuki called the teapots kats in the U.S. And even a bloomin' scooter got the moniker too , so what the heck we all know what's what don't we ?

Edited May 18 by DAZ
Spelling and grammar

[wraith]

2 hours ago, DAZ said:

Not really to be honest mate, especially in the oilcooled section , whilst I love an original Katana (who doesn't !?!) , there's plenty of fake ones about whether they're GSX based or Inazuma,or some other mongrel breed , and Suzuki called the teapots kats in the U.S. And even a bloomin' scooter got the moniker too , so what the heck we all know what's what don't we ?

Yes I can agree with you, we all have seen the gsx1400,gsxr1000, inazuma etc with kat bodywork on and the owners called them the gsx1400 kat etc. Suzuki called there different bikes katana, as you say from a 50cc rev and go to the last gsx1000 katana and of course the USA GSXF.

I'm not going to argue with Mr Suzuki what he calls his bikes, it's just the OSS bit, that the only katana is the original one, well apart from the popup headlight one 

And saying all that, the Katana Owners club UK or others will/do not recognise the GSXF as a katana 

Each to there own  but sometimes you just need to go with whatever sites rules you are on 

[Captain Chaos]

Google "Katana" and not a single aircooled Suzuki is found.

[Dezza]

It's just a word (that Suzuki never put on their original air-cooled machines). It may not appear that welcoming to potential new OSS members with oil cooled bikes with sodding great 'Katana' stickers as applied at the factory many years ago, getting bollocked on their initial posts for understandably referring to their bikes as 'Katanas.' I suggest the bollockings cease .

[DAZ]

@wraith, I absolutely agree about the site rules should be adhered to , but as @Dezzapoints out it's hardly  welcoming for our American cousins to be told to read the fuckin' rules 'cos your bikes a teapot not a Katana even though over there that's what they've been for the last 37 years,  the main thing is we are all here for our love of old school Suzuki's and keeping the problematic old buggers going  ...... The bikes not the owners obviously 

[Gixer1460]

The clue is in the club name OLD skool Suzuki - for most, that line or heritage stops mid 90's - even WC GSXR's and TL's are considered a bit moody for some! OSS was and is, primarily European / UK centric hence only one bike style was called 'Katana'! Just because the 'new colonies' decided to put stickers proclaiming katana on everything doesn't make it right - I don't think it was the factories choice, more than likely some sharp suited marketing man who's never ridden a bike! America is the ONLY place this occurs and unfortunately just because it does, does not make it acceptable. The rules are there and are quite clear - everyone has to read them when they join so no excuses, don't like the rules then you don't play with our train sets resources!