Broken Hex wrench doing sub-frame upgrade - Kawasaki KLR 650 Forum
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post #1 of 7 Old 11-07-2006, 03:45 PM Thread Starter
 
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Broken Hex wrench doing sub-frame upgrade

Broke the tip of my Bondus hex wrench trying to loosen the left side top sub-frame bolt. Not sure what to do now. Any ideas to get the tip out of the bolt head? I suppose drilling it the doing a bolt extraction is what I need to do, but as tight as it was, I am not going to worry much about it for now.
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post #2 of 7 Old 11-07-2006, 05:54 PM
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Re: Broken Hex wrench doing sub-frame upgrade

Quote:
Originally Posted by snowlover
Broke the tip of my Bondus hex wrench trying to loosen the left side top sub-frame bolt. Not sure what to do now. Any ideas to get the tip out of the bolt head? I suppose drilling it the doing a bolt extraction is what I need to do, but as tight as it was, I am not going to worry much about it for now.
Drilling should work. Have you thought about applying heat and a hammer to loosen the hex tip? I believe the upper sub-frame bolts are red Loctite'd and you might need heat to remove them.

Was there weight on the rear wheel when you tried to remove the bolt? If so raise the rear wheel off the ground. This should remove the weight of the KLR. Also were the lower sub-frame bolts installed when you tried to remove the upper bolts? They should be.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #3 of 7 Old 11-08-2006, 12:16 AM Thread Starter
 
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Rear tire off the ground, left side had new bolt in already, bottom stock bolts were still in. Should have tried heat. Guess that will be the plan next time.
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post #4 of 7 Old 11-12-2006, 08:52 PM
 
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I have been successful a tig welding a rod onto broken bolts etc.. and then having something to pull on... there might not be enough room.. but if you put the rod on one edge of the hex and then weld starting from the other side that might work...
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post #5 of 7 Old 11-13-2006, 09:57 AM
 
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Being a mechanic, I get lots of practice with broken tools and bolts. One of the many occupational joys.

To remove the broken hex tip, I would try drilling a pilot hole in it and then running a self tapping sheet metal screw into it. Then you can clamp the screw in vise grips and try to wiggle the broken tip out.

To remove the fastener, try heating the head of the fastener to cherry red. That will cause the fastener to expand in the threaded hole. Allow it to fully cool off. Then tighten it slightly if possible; this is to bust any garbilty-goop that is binding the assembly. Trying to crank it out without first doing a bit of tightening can cause any garbilty-goop in the threads to bind tighter. It should come right out after that. It is counter to what you would think to do but works very well.

Locktite melts at 240F if I recall correctly.

Garbilty-goop is a technical term that should be used with care, especially around wimmins & children.
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post #6 of 7 Old 11-14-2006, 10:07 AM
 
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Try some Superglue or epoxy another bolt or metal rod on the end to extract?

TW
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post #7 of 7 Old 12-03-2006, 03:03 PM
 
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+1

Quote:
Originally Posted by ham!
Being a mechanic, I get lots of practice with broken tools and bolts. One of the many occupational joys.

To remove the broken hex tip, I would try drilling a pilot hole in it and then running a self tapping sheet metal screw into it. Then you can clamp the screw in vise grips and try to wiggle the broken tip out.

To remove the fastener, try heating the head of the fastener to cherry red. That will cause the fastener to expand in the threaded hole. Allow it to fully cool off. Then tighten it slightly if possible; this is to bust any garbilty-goop that is binding the assembly. Trying to crank it out without first doing a bit of tightening can cause any garbilty-goop in the threads to bind tighter. It should come right out after that. It is counter to what you would think to do but works very well.

Locktite melts at 240F if I recall correctly.

Garbilty-goop is a technical term that should be used with care, especially around wimmins & children.
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