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[romfordwisp]

 Ive got a 2004 zx10r and i need to undo the front caliper bolts but who ever put them on last tightened them as hard as they will go and now they wont budge and the hexagon shape bit in them is starting to round off from trying to undo them, ive soaked them in wd40 but no luck so far. any other ideas please, cheers

[MontyD]

Where are you?  I rounded mine completely and Rob at RJS Mallory Park got it straight off.....he fitted Honda caliper bolts now with a hex head so no more issues.

[Prilla]

hit the head of the bolt with a hammer, this will help to free the threads as well as close up the rounded hex bolt. Failing that, get a torx socket that's just larger than the hex (can't recall offhand the size required) tap torx into bolt with the aforementioned hammer and undo. Don't be tempted to reuse the bolts though. 

[BDS]

Before you try anything, heat them up, a hot air gun or careful use of a blow lamp is best but a hair dryer is better than nothing.

[chaospunx]

It's happened to me before think I got them out with an imperial Allen key that was slightly too big and hammered that in as monty says don't replace them with the standard ones there made of cheese

[NinjaPaul]

When you do get them off and replace them, invest in a torque wrench (in case you haven't already) to make sure they're never over tightened again lol. 

[okjc250]

Just got over this problem on my 05 zx10 using the next size up torx bit and a hammer. Worked a great cheers