STRIPPED DOO THREAD-Help - 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 9 Old 09-02-2007, 10:25 AM Thread Starter
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Join Date: Aug 2007
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STRIPPED DOO THREAD-Help

Desperately seeking bright ideas.....Started doing the Doo, all went well until trying to remove the rotor with the Rotor Tool (Eagle).
Put on some grease, screwed it in by hand, then used socket and breaker bar.
Very tight, at first I thought it had come loose, but looking closer I noticed the bolt wasn't doing anything!!!!!!!!!!!!
The end result is that the rotor removal bolt is still in the rotor, I can't get it back out because the thread is STRIPPED. Not sure if the bolt has stripped or the rotor.


At my wits end...Does anyone have any ideas to get it out?

Last edited by willows; 09-02-2007 at 04:51 PM. Reason: added pics
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post #2 of 9 Old 09-03-2007, 08:51 AM
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Quote:
Originally Posted by willows View Post
Desperately seeking bright ideas.....Started doing the Doo, all went well until trying to remove the rotor with the Rotor Tool (Eagle).
Put on some grease, screwed it in by hand, then used socket and breaker bar.
Very tight, at first I thought it had come loose, but looking closer I noticed the bolt wasn't doing anything!!!!!!!!!!!!
The end result is that the rotor removal bolt is still in the rotor, I can't get it back out because the thread is STRIPPED. Not sure if the bolt has stripped or the rotor.


At my wits end...Does anyone have any ideas to get it out?
I'd call Mike at Eagle. I'm sure it's not the first time something like this has happened, and he's always helpful beyond belief!!

Here's his website. http://www.eagle-m-e.com/
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post #3 of 9 Old 09-06-2007, 05:06 AM Thread Starter
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Just an update. The bike still has it's rotor attatched and is sitting in the darkest corner of the shed while I sulk, I mean plan!

Took the bike to a local Suzuki Dealer, only 10miles away. He couldn't remove the rotor and was surprised at how TIGHT it was on!

Ended up taking it to the Kawasaki Dealer, 70miles away. They tried to remove it with 2 different pullers and an Oxy set.No success. They said I should have taken it to them in the first place as the bike is still under warranty 'til Dec.

I wrote to Kawasaki Australia in the hope of some warranty claim for the rotor due to it being put on too tight. Their response was to tell me it was my own fault because a mechanic had not done the work.
Fair enough, it is written in "black and white" in the warranty book.

Perhaps they could learn a little about Customer Relations from people like Fred at Arrowhead Motorsports and Mike from Eagle Mfg/Eng. The service I have recieved from these people is simply amazing!

At the moment Mike is working on a different type of puller to get my rotor off.
While I'm waiting I can fit my IMS Tank and change all the bolts to Stainless cup heads!
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post #4 of 9 Old 10-21-2007, 02:35 PM
 
Join Date: Oct 2007
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I learned this trick from an old timer. There was a bearing race that was frozen/stuck and I couldn't get it out to save my like. I beat on it, pulled on it for hours. The old man walked over to me and said go get me a torch and a bucket of water. So I did.
He heated just one section of the race till it was HOT and then poured the whole bucket of water on it so it was cooled real fast. The race popped right out with a few taps.

He told me that once the metal expands from the heat that you applied in that one spot that you want to cool it very quickly (just in one spot) so it contracts. When it cools the heated "spot" contracts to a slightly larger/smaller size depending on OD or ID and allows some clearence.

I don't know if this will help but it sounds like you need some new parts anyway. Might be worth a try.

Good Luck to you.

Regards,
John
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post #5 of 9 Old 10-21-2007, 05:47 PM
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I've done the same thing with larger bearings, and running beads of weld with a TIG torch across the face of the race, in 6 or so spots, and then cooling it down with ice..
A race that you swore wouldn't come out, pops out with a couple taps..
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post #6 of 9 Old 11-12-2007, 03:01 PM
 
Join Date: May 2007
Posts: 36
stuck bolt

Sounds bad...seems the dealers are never any help..most of them have this problem...their usual motto is "bring money we fix"..their are some good dealers that will go out of their way to help a customer out..especially in a jam. My idea of a good dealer is one that would host a KLR tech day for all the KLR riders..basic service tips and whatever..and have a slice of pizza and meet some new friends...

The only dealer that I know to do that was Budds BMW in Oakville ..great bunch of service guys and always willing to give advice....Karl
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post #7 of 9 Old 11-16-2007, 10:56 PM
 
Join Date: Oct 2007
Posts: 94
I just got my doohickey kit, not in yet, I don't know how much room you have. But with two people, one person puts an open end wrench or a bar with a notch ground in the middle over the bolt and pulls like hell outward while the other person slowly turns the bolt in the out, counter clock wise direction. It puts enough force on it to make it bite into any exsisting threads. You're gonna need a keensert or something along that line to put back in there for threads. But like I said, I haven't been into mine yet and a number of things may get in your way. Try not to use a helicoil if its the 130 #ft torqued bolt. Keenserts are so much harder, usually than the metal they are repairing.
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post #8 of 9 Old 11-29-2007, 11:23 PM
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Join Date: Nov 2007
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im a pay the man to do it type person

how long until the do needs doing
my 08 is 1 week old
i tried to pull apart and fix my mildly broken laptop
now i have a really broken laptop and need to see the man
hope you get it fixed soon
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post #9 of 9 Old 11-30-2007, 08:28 AM
 
Join Date: Oct 2007
Posts: 94
Went back and re-read your first statement, man big problems, no way to get around it and the rotor is going to be shot. No help to you, but when I took mine off, it was tight also, I'd tighten it up a little and tap the removal tool with a heavy plastic hammer, something to vibrate the rotor just a little, came right off, lot of sweat on worring about stripping the thing. The spring was broken on the "do", in mine.
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