Torque wrenches are $14 on ebay. Buy one and save yourself a TON of hassle.

http://cgi.ebay.com/New-Needle-Torqu...3A1%7C294%3A50

 

I. ****ING. LOVE. THESE!

The amount of time these dumb things have saved me is incalcuable. I originally got them for dismantling ancient mainframe servers where some tech rounded off the screw by using the wrong size bit (stuff was weird in the 80's\90's), but I just recently had to use them on my bike.

You know those little clamp screws wayyyyy inside that hold the carbs onto the engine? The dumb**** dealer who installed the jetkit rounded off TWO of them. My buddy's Snap-On extractor kit was totally useless in there, but the grabbits had em out in literally SECONDS. They're $20, and every single mechanic \ handyman \ "guy who constantly breaks stuff" on the planet should have a set.

http://www.acehardwareoutlet.com/(0t...px?sku=2192573

 

Also, +1 on the service manual and torque wrench. While rebuilding my front end, I was surprised at how "loose" most of the bolts go on. I'm used to just cranking things down as hard as you can on cars, but bikes appear to be quite a bit more sensitive.

 

i had the same problem put some vice grips on the bolt tight, with palm of the hand tap up and down should loosen it up i gauranty it will loosen, my bolt there was nothing there lol came off with vice grips

 

I'm going through the same thing, I changed the oil last year ('99 CBR 600). Tried changing the oil over the weekend and I stripped the head of the bolt (I'm assuming I overtightened the bolt last year). I'm considering getting the "bolt out" set at sears....jamie9002, you mentioned vice grips, your referring to the quick adjusting, locking pliers, or grove lock. Any info from anyone is welcomed. Tks in advance.