i recently purchased an 06 king quad and i went to remove the spark arrester out of the stock pipe and whoever had it before me almost rounded out the head in the screw any suggestions?

 

Take a hack saw and cut a slot in what is left of the screw head. ?Then use a slotted scrwew driver to remove the screw.

 

Since it is an allen head you may get lucky and be able to get the right size allen wrench to back it out. Most likely the previous "mechanic" used an undersize wrench, SAE or metric, and may have left you some corners to work with.

If this does not work you have to make a choice. Drill or weld. To drill it out at least you have a centered hole to start from. Select a bit that fits the hole in such a manner as to drill it centered. The go a little bigger but leave enough of the screw or bolt to allow the use of an EZ-Out. Optionally you can keep going to bigger bits till you have just a thin shell left of the screw and break it out with a small chisel and needle nose pliers. Usually I will drill a stud out till I start seeing threads on one side before I start trying to break it out.

If you elect to go the weld route, and have enough material to weld too, just tack weld in three or four places around the end of a bolt slightly smaller than the screw and use the head on the bolt to back out the screw.

Whatever method you use I would soak the screw/bolt with a penetrating oil for a few hours and, if possible, give it a few sharp raps with a hammer prior to trying to turn it. Often times adding some heat from a torch will also help.

Lots of patience is required for these kinds of problems. Good luck.

 

Actually this is a common problem on the 700, several tips, as you have already read, you can use vice grips and assist with an allen wrench, get new bolts and apply never seize.

 

you can try tapping on the allen wrench while trying to back it out w/ a small hammer...

A back out tool would probably be less intrusive than drilling it out... I would leave drilling as a last resort, as you might mess up and have to re-tap the hole....