How do you remove these??? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 8 Old 12-08-2013, 10:31 AM Thread Starter
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How do you remove these???

I want to remove the ignition switch from the top triple clamp and saw these two fasteners on the back. Have never seen these before. Normally I would beat the crap out of them and regret it afterwards, but I thought I would take a more mindful approach and actually figure out how they should be removed. How do you remove these?
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post #2 of 8 Old 12-08-2013, 05:28 PM
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It looks like a rivet. Pick a side and a drill bit about the size of the pin. Drill the pin/shank enough to get the tab/head to come off, then drive it out with a punch.

After you drill the washers off, the pins should be easy to punch out.
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post #3 of 8 Old 12-08-2013, 07:42 PM
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Those bolts once had heads on them. They are a security bolt where the head shears off once sufficient torque has been applied.

It looked like this before it was installed:


To remove them use an appropriate size EZ-out, or very carefully drill the remaining bit of head off with an 8mm drill.

T

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“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

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Last edited by Tom Schmitz; 12-08-2013 at 07:56 PM.
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post #4 of 8 Old 12-08-2013, 07:56 PM Thread Starter
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I thought it was very weird the way it looked - like how could they engineer something like this that can't be easily removed? The bike is pretty beat up so I am not surprised the heads of the bolts are sheared off. Thanks for the replies.
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post #5 of 8 Old 12-08-2013, 08:20 PM
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No, no, they are designed to be sheared on on installation. It's so that someone can't easily remove the ignition switch either to steal the bike or after stealing it. The intent of the design is precisely to make the ignition difficult to remove.

These things have been used on automotive ignition switches and column locks for the last 45 years.

There's probably some NHTSA regulation...

T

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #6 of 8 Old 12-08-2013, 09:09 PM Thread Starter
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You learn something everyday! Thanks for the insight. I guess I will remove and replace with a regular threaded bolt. Bike is so beat up I don't worry about anyone stealing it.
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post #7 of 8 Old 12-09-2013, 01:31 AM
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Left hand drill bits work well for this purpose. As Tom advised, use an 8 mm of there abouts and turn the drill on the slow side. They will usually just thread out with the torque of the drill bit but if not the head will pop off. Once the head if off, drill the shank of the drill and remove as usual with an easy-out as Tom recommended.

Not likely but possible that the thread is left handed. I've done several bike ignition locks with break-away bolts and a pile of automotive but don't recall any bikes using left hand. There is, however and increasing unreliability of memory as I age.

I've even reinstalled some break-way bolts using the same square tapered EZ out as used to remove. Had to swap the lock and no parts available.

HIH

Norm
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post #8 of 8 Old 12-09-2013, 10:58 PM Thread Starter
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Drilled it and used an ez out to pull both out. Worked like a charm. Thanks for the info. This is why I love these forums. They stop me from doing something stupid - usually.
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