S$#! Snapped off bolt in Tail frame. Ideas? - Kawasaki KLR 650 Forum
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post #1 of 9 Old 04-23-2017, 06:14 PM Thread Starter
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S$#! Snapped off bolt in Tail frame. Ideas?

Ok, i installed the BRE tail plate with the pelican case. Loved it. As I was riding the other day i got off bike and noticed that the entire tail could be lifted up. Got home and figured out the bolts had sheared off inside the frame. I was able to easy out one of the bolts, but broke the easy out off in the screw. What are the options with regards to fixing this? Install new frame piece? is that even possible? Buy a new bike, maybe a KTM? LOL, just joking. Would appreciate some options from the experts.

Thanks,
Pat
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post #2 of 9 Old 04-24-2017, 05:22 AM
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The exact same thing happened to me about two weeks ago. It was the second time those bolts had snapped. I left the snapped bolts and instead used three hose clamps by cutting a groove in the rear rack and plastic. The hose clamps wrapped around the frame and the rear rack holding it in place. So far so good.


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post #3 of 9 Old 04-24-2017, 07:14 AM
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Broke one of mine too and bent the other. I was able to get it back out but messed up the threads. I drilled them all out and tapped them the next size bigger. Huge improvement!

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post #4 of 9 Old 04-24-2017, 08:42 AM
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Not sure exactly which bolt we're talking about; I drilled through the two bolt-holes angled upwards from under the rear of the seat; tapped completely through, and installed longer high-strength bolts. Too late now for the OP's problem, but worth consideration for the future.

Broken E-Z Out remains a challenge; have drilled 'em out, but . . . don't want to do it again!
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post #5 of 9 Old 04-24-2017, 12:07 PM
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Quote:
Originally Posted by navydive View Post
Ok, i installed the BRE tail plate with the pelican case. Loved it. As I was riding the other day i got off bike and noticed that the entire tail could be lifted up. Got home and figured out the bolts had sheared off inside the frame. I was able to easy out one of the bolts, but broke the easy out off in the screw. What are the options with regards to fixing this? Install new frame piece? is that even possible? Buy a new bike, maybe a KTM? LOL, just joking. Would appreciate some options from the experts.

Thanks,
Pat
With the rear fender plastic removed and the rack provided for locating the mount, a good welding shop could cut the old 6mm nut with broken 'easy-out' Out!
And then weld in 8mm nuts in both of the rear rack center mounts.

Drilling clear thru that rear frame loop is Not a good idea for several reasons, imho (water entry/rust thru/freeze break/ general weakening). But people have done it.

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post #6 of 9 Old 04-24-2017, 03:43 PM Thread Starter
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hanks guys. Appreciate the input. I figured i wasnt the only one with this issue. I may try the coming up underneath and see if i can spin it out. i have already snapped 2 titanium drill bits trying to get that damn easy out. I guess they werent lying when they said not to break it off.
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post #7 of 9 Old 04-25-2017, 10:19 PM
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The 6mm stock bolts are to small for a loaded rack on rough roads. Those 6mm nuts are just barely tack welded in their mounting brackets. You can tap them out sideways with a chisel. Then screw short 8mm bolts through 8mm nuts in the brackets and pack them with JB Weld to make them captive. Replace the original 6mm bolts with 8mm and you are done.
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post #8 of 9 Old 04-27-2017, 06:03 PM
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Quote:
Originally Posted by GoMotor View Post
The 6mm stock bolts are to small for a loaded rack on rough roads. Those 6mm nuts are just barely tack welded in their mounting brackets. You can tap them out sideways with a chisel. Then screw short 8mm bolts through 8mm nuts in the brackets and pack them with JB Weld to make them captive. Replace the original 6mm bolts with 8mm and you are done.


That what I was originally planning, however the snapped bolt extractors made drilling out the 6mm near impossible.


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post #9 of 9 Old 04-27-2017, 11:22 PM
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Originally Posted by tristanvons View Post
That what I was originally planning, however the snapped bolt extractors made drilling out the 6mm near impossible.
There is always a way if you are determined. Break the captive nuts loose from their brackets. You need to get rid of them anyway and go with 8mm nuts and bolts. Mine were barely tack welded in. Tap sideways on them. Tap down on them. Drill sideways into them and then tap on them.

When I say tap on them I mean beat on them just hard enough not to damage the brackets.
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