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Hey guys, great site. My buddy Dan has been riding a KLR for several years, and after riding it for the first time, I decided I have to have one, so I've been shopping...

He did his doo several years ago, and offered to help a fellow KLR guy do his. He broke the wrench, which was cast aluminum, so he called me, knowing I like making stuff like this, so I easily fashioned one out of a Chinese 1-1/4" wrench. Knowing how cheesy the old wrench was, we should have known that the puller was probably designed to only work one time as well.

While threading the puller in, after it made contact with the crank, it completely stripped out, and now it won't come out. It's obviously very mild steel, because we were able to drill a hole perpendicularly through the hex area to insert a screwdriver shaft, hoping to use it as a sort of t-handle, so we could get the threads started and back it out (which also didn't work). I thought maybe we could hack the hex part of the puller off (which we haven't done yet), and drill a dimple in the center to use as a guide for a 3-jaw puller, but I don't know if there's anything for it to grab onto, while avoiding damage at the same time. I'm thinking that this is not a good problem to say the very least...

I know what you're all thinking- "Oh boy, I'm sure glad that's him, and not me!" I'm thinking that as well, but thought I'd help in any way that I can, and when I get a KLR, he'll owe me one! This is a classic example of "You get what you pay for". I'd be willing to bet if he had this to do over again, knowing what he knows now, that he would gladly shell out a hundred bucks for better tools. Whaddaya think? Anybody have any suggestions other than "You're screwed, dude."? Thanks in advance!
 

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Hey guys, great site. My buddy Dan has been riding a KLR for several years, and after riding it for the first time, I decided I have to have one, so I've been shopping...

He did his doo several years ago, and offered to help a fellow KLR guy do his. He broke the wrench, which was cast aluminum, so he called me, knowing I like making stuff like this, so I easily fashioned one out of a Chinese 1-1/4" wrench. Knowing how cheesy the old wrench was, we should have known that the puller was probably designed to only work one time as well.

While threading the puller in, after it made contact with the crank, it completely stripped out, and now it won't come out. It's obviously very mild steel, because we were able to drill a hole perpendicularly through the hex area to insert a screwdriver shaft, hoping to use it as a sort of t-handle, so we could get the threads started and back it out (which also didn't work). I thought maybe we could hack the hex part of the puller off (which we haven't done yet), and drill a dimple in the center to use as a guide for a 3-jaw puller, but I don't know if there's anything for it to grab onto, while avoiding damage at the same time. I'm thinking that this is not a good problem to say the very least...

I know what you're all thinking- "Oh boy, I'm sure glad that's him, and not me!" I'm thinking that as well, but thought I'd help in any way that I can, and when I get a KLR, he'll owe me one! This is a classic example of "You get what you pay for". I'd be willing to bet if he had this to do over again, knowing what he knows now, that he would gladly shell out a hundred bucks for better tools. Whaddaya think? Anybody have any suggestions other than "You're screwed, dude."? Thanks in advance!


Contact Eagle Mike the guy that makes the aftermarket doo. He's very helpfull from what I've read.

I would think that you could heat the bolt and use an impact wrench, seems logical but I would ask Mike first.
 
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