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Posts: 214
Since: 22/3/2007
Status: offline
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Evening,
I have now mastered the problem of the little bushing / riv nut spinning and therefore not allowing you to remove the bolt / screw - ie they both spin together.
There are 3 on each headlight 2 at the front and one accessed from behind the light - you need to remove the airbox to get at it. It can be tricky to drill out the head of the bolt as everything spins but if you can wedge something against it you can drill them out. The same with the spinning riv nut you need about a 7mm hss bit to drill it out.
The one at the back of the headlight was difficult as you can't actually see it, but with a 2ft long flexible drill extension i you can get at it. In drilling out the rear nut i enlarged the shape of the hole so the hole was too big/ uneven for the new riv nut. My cunning plan was to make a small plate from aluminium fix the riv nut to that and then rivet this to the headlight. When you fit them pack them with grease so the new bolt can not seize in the riv nut.
To "pull" the riv nut i used a long bolt M5 bolt an M5 nut larger M6 nut and a couple of washers, you can buy a tool for £20 plus but this way worked really well. I have replaced 6 so far and want to do a couple in the wheel well. The headlight bracket is not that rusty, the picture makes it look worse.
Del
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