Sometimes You Just Can't Win - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

 
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post #1 of 4 Old 10-31-2012, 08:53 PM Thread Starter
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Join Date: Oct 2012
Location: Silver City, NM
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Sometimes You Just Can't Win

Last week I added the soft plastic Tusk hand protectors to the aluminum...uh...guards and the odd ball sized allen bolts gave me fits. About the same time my new Eagle-Mike front forks brace came in and I had fits with the odd sized bolts again.

5mm was too sloppy and we all know how easy it is to round out the end of the wrench and chew up the inside of the bolt, eh ?? 5.5mm was too big and wouldn't fit. I have 2 sets and tried both. I also tried the SAE wrenches and none were even close. Hmmm.......??

I did say some bad words.....and a few more when I tried getting those stubborn bolts out of the handlebars....but they did come.

Sooo.....I did some Koostum engineering......



I very, very carefully filed down an extra 5.5mm allen wrench to precisely fit my oddball allen bolts and it did the job just fine. Precision Lar.

But it bugged me. Who ever heard of oddball commercial sizes and from 2 highly respected suppliers ?? Later that night I couldn't stand it and went out with flashlight and micrometer. (what I should have done to begin with)

Well, my 5.5mm wrenches were just about right....but the 5mm's miked at 4.8mm and 4.85mm. Have you ever heard of such a thing ?? Nor have I.

What Fun, eh ??............Lar.
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post #2 of 4 Old 10-31-2012, 09:01 PM
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Location: Pismo Beach, CA
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You must have bought the "quality" allyn wrenches at Harbor Freight.
Chinese craftsmanship? at its BEST?????
I always use allyn hex sockets to work on my bike. They fit properly and don't round off your tools or bolts.
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post #3 of 4 Old 11-01-2012, 12:37 AM Thread Starter
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Quote:
Originally Posted by pismocycleguy View Post
You must have bought the "quality" allyn wrenches at Harbor Freight.
Chinese craftsmanship? at its BEST?????
I always use allyn hex sockets to work on my bike. They fit properly and don't round off your tools or bolts.
No, I only buy from HF in cases of desperation. I prefer to avoid Chinese made whenever possible or practical, tho' it's very difficult anymore. I've had these 2 sets for many years, but mostly used the SAE set. I've been buying allen head sockets for my 3/8" drive, so that should cure that problem.

Thanks...........Lar.
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post #4 of 4 Old 11-01-2012, 04:37 AM
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Problems such as that are frustrating. I often make up new cuss words/phrases when faced with things like that.

Sometimes regardless of the tools and fasteners used production tolerances meet in the wrong way.
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