Broke Subframe Bolt - Kawasaki KLR 650 Forum
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post #1 of 21 Old 12-29-2011, 04:17 AM Thread Starter
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Broke Subframe Bolt

I rode my bike into work one day last week, about halfway there while on the highway I started to hear a new vibration noise. It sounded similar to when my old crashbar broke due to the vibes. (SW Motechs). A couple quick diagnostics without slowing down confirmed my suspicion that the noise was coming from my crashbar. I looked at it that night before riding home and could only figure that one of the front mounting point bolts was loose. I was going to ride off to lake tahoe first thing tomorrow morning, so tonight I decided to go and tighten that bolt. It maybe was loose, not positive. I loosened, cleaned, relocktited it, tightened it. I still had the same flex and vibes. I found that my left subframe bolt had sheared. I was using the bolts that came from Twisted Throttle in the crashbar kit.

What's the best way to remove the sheared part of the bolt?

Do the EM bolts work with the Motechs?

Thanks!

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post #2 of 21 Old 12-29-2011, 04:19 AM Thread Starter
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I now see that EM has a Motech specific bolt.

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post #3 of 21 Old 12-29-2011, 08:58 AM
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You might have to drill it out or use a bolt extractor thing...

Did it shear right off and is flush with the frame? Sometimes with broken bolts it there is enough sticking out you can back it out with your fingers.

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post #4 of 21 Old 12-29-2011, 11:03 AM Thread Starter
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The bolt is broken about 1" inside

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post #5 of 21 Old 12-29-2011, 01:04 PM
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I had a sheared off subframe this past spring. It was sheared flush and locktited in. I predrilled the sheared bolt and used a bolt extractor. It was tough to remove but once I applied enough heat with a blowtorch it eventually backed out.


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post #6 of 21 Old 12-29-2011, 02:49 PM
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Quote:
Originally Posted by kmbsar View Post
The bolt is broken about 1" inside

Try to turn it with some sort of chisel like object. Use a hammer and tap it working around the perimeter.

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post #7 of 21 Old 12-30-2011, 08:36 AM
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Try to turn it with some sort of chisel like object. Use a hammer and tap it working around the perimeter.
If that doesn't work, a small center punch, will sometimes drift a screw around if you let it push from the outside, and the unscrew..

I bought a set of extractors years ago. Spiral extractors are pretty cheap, and will do the job.. Take your time and don't rush it.. A bit of penetrating oil might help get the screw out, too.

While I'm not riding a Gen 2 bike, I'm using an EM designed subframe bolt kit, going with the oversized and harder fasteners.
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post #8 of 21 Old 12-30-2011, 11:51 AM
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Quote:
Originally Posted by kmbsar View Post
What's the best way to remove the sheared part of the bolt? Thanks!
Had as similar experience with a different scoot. Worked on it a whole day with drill/ screw extractor with no luck. Finally took it to a local machine shop that took care of it in short order. Seems like it was less than $20..

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post #9 of 21 Old 12-30-2011, 12:07 PM
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Quote:
Originally Posted by kmbsar View Post
I rode my bike into work one day last week, about halfway there while on the highway I started to hear a new vibration noise. It sounded similar to when my old crashbar broke due to the vibes. (SW Motechs). A couple quick diagnostics without slowing down confirmed my suspicion that the noise was coming from my crashbar. I looked at it that night before riding home and could only figure that one of the front mounting point bolts was loose. I was going to ride off to lake tahoe first thing tomorrow morning, so tonight I decided to go and tighten that bolt. It maybe was loose, not positive. I loosened, cleaned, relocktited it, tightened it. I still had the same flex and vibes. I found that my left subframe bolt had sheared. I was using the bolts that came from Twisted Throttle in the crashbar kit.

What's the best way to remove the sheared part of the bolt?

Do the EM bolts work with the Motechs?

Thanks!
Gees dude try loosing some weight! You're obviously too massive for a KLR.
I really like the Alden Drill-out. They drill and remove in a ccw direction Should be an easy removal w/o tension on the broken bolt.

Last edited by SLO-KLR; 12-30-2011 at 12:14 PM.
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post #10 of 21 Old 12-30-2011, 12:20 PM
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If you're fitting the EM through bolt you could drill right through it if necessary...

Not a fan of extractors personally, break one of those and you're screwed, very hard to get out.
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