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gvkohl
01-23-2007, 03:14 PM
Is there an easy way to get the ignition swith off of the top triple tree?

I had a spare top triple that I was going to paint and just found out that the ignition is held on with the bolts from hell.

Any tips, tricks or ideas?

HS2020
01-23-2007, 03:50 PM
Umm what year is your bike :?: I know that on my pre98 750 all I had to do was remove the allen head bolts on top of the tree. You should not have to remove the upper tree to do this. I had mine painted to match my bike. Never had to remove the ignition at all.

gvkohl
01-23-2007, 03:57 PM
Mine is an 02. The ignition switch is held on from underneath by two torx style bolts. But the bolts have a "post' in the center. Even the dealers do not have the wrench to remove these.

arsenic
01-23-2007, 04:19 PM
the bolts that hold the igniniton switch in are called shear head bolts. They are a royal pain in the butt. The only wau to get the them off is with a punch and a hammer. It's beat to put the top tree in a vice, use blocks of wood if your gonna reuse it. Then take the punch stick it in the hole and knock the bolts counter clockwise. If you don't need the top tree again, just take a chisle and wack place where bolts go. Not having to stick the punch in there makes it a lot eaiser.

gvkohl
01-23-2007, 06:23 PM
Is it possible to drill out the center "post" and then use a torx wrench of allen wrench to remove it?

Why doesn't a dealer have a tool to remove it? Isn't that kinda crazy?

arsenic
01-23-2007, 06:32 PM
there is no wrench to remove it. I worked at a Suzuki dealership, trust me what I said is right. Thoughs shear head bolts are torx head bolts when you put them on, when you reach a preseet torque setting the heads shear off, a hammer and a punch is the only way to get them off. If some of the members said they are different they are not stock, the stock ones are shear head bolts. If you don't want to take my advice, look at any manual they will tell you the exact same thing.

gvkohl
01-23-2007, 07:00 PM
HEY....I believe you. I don't have any reason not to. I was just hoping for a simple solution.

Your answer begs a question though. If they sheared off, wouldn't I then be able to get the ignition off...then use something like vise grips to get the bolts out?....just a thought.

arsenic
01-23-2007, 07:24 PM
no you cant use vice grips because you have to fit them up inside the hole where the bolt goes. The vice grips won't fit in there, plus there is nothing to grab onto. So in short there is no simple answer. Those shear head bolts are a saftey measure put there for a reason, and probly one of the hardest things to do on a motorcycle.

arsenic
01-23-2007, 07:30 PM
But talk to HS2020, he has a painted top tree, and if he says you don't need to take that out, he would be the one to talk to.

KatDan
01-23-2007, 09:22 PM
my SV has the same bolts, should be a T40 security torx bit. as far as a shear bolt, my service manual doesn't say anything about that. i need to take mine out anyway, i can let you know tomorrow if they shear off or not.

HS2020
01-23-2007, 09:25 PM
Both of you post up some pictures of your top triple tree. That way I can look at them and be able to tell.

Dan I know you will figure it out and post up some pictures if not then I will have to :slap: you. :lol:

KatanaSoldier
01-23-2007, 09:55 PM
:worthless: :shootdw: :shootdw: :shootdw:

gvkohl
01-23-2007, 10:11 PM
had my triple tree off earlier today and didn't get any pix. I won't have it off again for another week or so. Hopefully KatDan will have some pix and I can verify that mine are the same.

arsenic
01-23-2007, 10:11 PM
granted he has an 02, and this is a pre 98 factory service manual. here is what it says:
To remove the ignition switch, remove the bolt to detach the ignition switch from the steering stem upper bracket by using a center punch and a hammer.
To install the ignition switch, always use the new special bolt and follow the procedure below.
Using the special bolts, attach the ignition switch on the steering stem upper bracket in place and run in the bolts with the special tool (torx wrench)
Continue turning the tool until the tool slips from the bolt head or the bolt head breaks off, then the bolt has become tightened to the proper specification.
that is directly from the manual. Chassis section page 7-25
So for the pre 98's I'm sure they are shear head bolts as for the 98+ kats maybe I'm wrong.

KatanaSoldier
01-23-2007, 10:15 PM
had my triple tree off earlier today and didn't get any pix. I won't have it off again for another week or so. Hopefully KatDan will have some pix and I can verify that mine are the same.

:lol: Just busting your chops.

arsenic
01-23-2007, 10:29 PM
Ok I just looked at the 98+ manual, the downloadable version on this site and it just says remove the ignition switch with a trox wrench, so maybe they are those security bolts, didn't say anything about the shear head bolts. If so you really got lucky there, those shear head bolts really suck!

arsenic
01-23-2007, 10:58 PM
Okay just talked to CP, he knows everything about katana's. The bolts you have on the are shear head bolts. here's some examples of security bolts http://www.brycefastener.com/ Maybe you could use those when you put it back on, or you can certainly see what you have there are not security bolts.

The CyberPoet
01-24-2007, 12:28 AM
Sears carries a line of tamper-proof bits for removal of some tamper-proof bolts. You might get lucky and find a match in their collection (visit sears.com and search tools for the word tamper).

I've never had to remove a Katana ignition (fortunately keys are cheap to get extras cut at time of purchase), but all motorcycles on the market generally use tamper-proof bits of some sort (otherwise the idea of an ignition lock would be pretty useless -- you could just unscrew it).

Cheers,
=-= The CyberPoet

gvkohl
01-24-2007, 07:38 AM
I got my hands on a Haynes manual and it says the bolts are called secure torx bolts. It simply says to remove them with a secure torx bit. It doesnt talk about them being shear bolts. It just says to get the special tool and use it.....so I will get the bits and let you guys know what happens.

I checked the internet and most good stores have them. They are readily available.

It will be next week before I get a chance to give it a shot, but I will let eveyone know how it goes and will take pics in the process.

arsenic
01-24-2007, 07:55 AM
Okay, best of luck!

steves
01-24-2007, 08:46 AM
Sears carries a line of tamper-proof bits for removal of some tamper-proof bolts. You might get lucky and find a match in their collection (visit sears.com and search tools for the word tamper).

I've never had to remove a Katana ignition (fortunately keys are cheap to get extras cut at time of purchase), but all motorcycles on the market generally use tamper-proof bits of some sort (otherwise the idea of an ignition lock would be pretty useless -- you could just unscrew it).

Cheers,
=-= The CyberPoet
Harbor freight also sells security bit sets...

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=91310

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=93388

Mr. Clean
01-24-2007, 12:05 PM
On my 2002 they are secure torx head bolts with red "super" loctite on the threads. And they are a PITA to get out but they WILL come out with the right tools. You need the secure torx head bit. I bought mine at sears and I picked up an entire set at Harbor Freight Tools later on. Also get yourself a hand impact. It work by you hitting it with a hammer. Yeah sounds messed up but it works.

KatDan
01-24-2007, 01:21 PM
i just took mine out and it does NOT use shear bolts, they are t40 security torx bolts. i will post pics tonight for anyone interested.

KatDan
01-24-2007, 09:44 PM
sorry i didn't get pics yet, had to work late. i will get some if you still need them. i also had to edit my last post, it's a t40-not 45.

gvkohl
01-25-2007, 08:56 AM
KatDan.....any issues getting them out? Red locktite? Impact required?