Radiator cowl bolts - argggh

[Eville Rich]

I feel like the biggest idiot, but I'm having a devil of a time getting the bolts that hold the radiator cowl. These are the 4mm allen head bolts that you can see from the side (plus one at the top). Last fall I needed to remove the cowl and was able to get all but one reinserted and happy. That last one was a bugger and I decided to put it away until spring (winter storage and such). Today I decided to take another look at it and couldn't get that last one in. I decided to pull the others out and see if I could get it started, but no dice. And now I have a total of three that won't back on. I decided to put things away and return to it another day.

For the life of me, I cannot figure out why these stupid little bolts are so hard to get threaded. I've tried multiple angles, made sure the holes are lined up with the plastic, etc. I can get the threads to contact and did the "reverse until the threads connect" trick. But all to no avail.

What's maddening is that I've done this all before and had no issues.

What is the deal?

Eville Rich
2016 S10

 

[Tenforeplay]

I was having trouble with one so loosened the others so I could jiggle the cowling and finally got it started. Can’t remember ever having so much trouble getting a fastener started.

 

[holligl]

I used to have lots more problems. I would try to start them with a power driver. I learned to simply start them by hand using minimal pressure. Visually check the alignment before starting each one. Don't tighten any until they are all started.

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[escapefjrtist]

Issue I have is they all seem to be at different funky angles. Once you find the sweet spot, starts easily. Important not to force and cross thread as that doesn't end well. Take a break, figure out the angle they're at and you'll be golden!

Good luck!

~G

 

[Jlq1969]

Issue I have is they all seem to be at different funky angles. Once you find the sweet spot, starts easily. Important not to force and cross thread as that doesn't end well. Take a break, figure out the angle they're at and you'll be golden!

Good luck!

~G

I think that's the point...the screw angle does not coincide with the "supposed" visual angle...once the screw angle matches, it screws smoothly

 

[Sierra1]

. . . . I would try to start them with a power driver. . . .

Braver than I. I never start anything with power anything. (Don't ask me why )

 

[Cycledude]

Ive have the same problem every time I removed the left cowl , you need to get your fingers behind the plastic tab and press out while very carefully attempting to get the screw to start threading, seems impossible but it works, actually works better with 2 people. Definitely don’t use a power tool to get any of those screws started !
Yamaha really should redesign those parts and make it much easier to service the radiator.

 

[TenereGUY]

I 2nd what Cycledude said. I was cursing the engineers who just didn't put those wonderful 1/4 turn bolts on the left side too earlier this week. Then I found out if I sneak my finger behind the threaded clip and push it to the screw it goes on fairly easily. What I think is causing all the consternation is that when we push the bolt in it then pushes the clip back so it doesn't thread in no matter how hard you push the bolt. just sneak your finger back there and you'll be happy. I could always come up and give you a hand or moral support.

 

[patrickg450]

the back moves away when under pressure, use a screwdriver or something to "hold" the back while you start it

 

[Eville Rich]

I'll try a screwdriver for back-pressure. My initial problem one was the front bolt, above the lowest bolt. I couldn't find a way to get around to the back side, other than on the black plastic piece - it's a barrier to the actual threaded clip.

Weather is getting good and last night's rain took away most of the residual roads salt, so it's time buckle down and get this sorted.

Eville Rich

 

[TenereGUY]

I'll try a screwdriver for back-pressure. My initial problem one was the front bolt, above the lowest bolt. I couldn't find a way to get around to the back side, other than on the black plastic piece - it's a barrier to the actual threaded clip.

Weather is getting good and last night's rain took away most of the residual roads salt, so it's time buckle down and get this sorted.

Eville Rich

Yes, that was the one that 1st gave me trouble and then 2 more toward the back.

 

[Eville Rich]

I threw in the towel on the last OE bolt. Ended up using a M5 20mm bolt on the last one. The last one to give me trouble was the bolt hole closest to the seat - upper right if looking at the cowl from the side. The 20mm was a bit longer than I'd have liked, but with a couple of washers wasn't too bad. At least it would catch the threads and engage. I may see if I can find one with an Allen head.

Just passing along in case anyone has similar issues. M5 bolt. No longer than 20mm and use a couple of washers to spread the load across the bolt hole area. My washers were if different sizes - the smallest fit the bolt head, the next a little wider to spread the load. Would have like a wave washer to help with retention, but not a big deal, I think.

Eville Rich
2016 S10

 

[TenereGUY]

Hey Rich,
I could see if I have a die that will match that bolt. If I do you could bring it down and I could clean the threads up and it might grab then? I am gone the next two weeks though. After that won't be a problem.

 

[Eville Rich]

Hey Rich,
I could see if I have a die that will match that bolt. If I do you could bring it down and I could clean the threads up and it might grab then? I am gone the next two weeks though. After that won't be a problem.

Thanks for the offer, but I don't think it was a bolt or thread issue. I think it's either an issue with how the plastics are sitting, or an issue between my ears. I may return to do battle and get the OE bolt to work, but I may just monitor things or see what I can find in a slightly longer button head Allen bolt.

Eville Rich
2016 S10

 

[Scott F]

I had the same issue yesterday when I changed my radiator juice. I ended up sliding off the clip the bolt screws into (literally, all of them one at a time...) and noticed the slight angle the screw must be inserted with. It still was a frustrating job but in the end they are all back on - the key is finding the angle.

If you envision the clip as a "C", you have to angle the bolt very slightly into the "c". Probably doesnt make sense.
I could show you but you'd have to come to Stuttgart Germany to see it...

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