Removing Rounded Allen Bolts
 

Trying to remove the stock rearsets as I've bought some shiny new ones. The Allen bolts holding the rear brake master cylinder are totally rounded.

Any ideas?

Re: Removing Rounded Allen Bolts
 

Will be watching this as I've got the exact same problem, the only thing I can think of is drilling them out and hoping not to muller the MC but as it's not a pressing issue I've avoided that so far.

Re: Removing Rounded Allen Bolts
 

I've tried drilling already but I don't think I'm doing it right as it just made them even rounder.

Re: Removing Rounded Allen Bolts
 

I use a dremel to cut a GOOD slot in them then if they are too tight to get with a good tough hollow ground screwdriver bit in a socket, I get out the impact driver. When replacing use copper grease on the thread so it never happens again. In fact while you are at it, go round your bike removing all unimportant screws and greasing the threads while you can still get them out.

Re: Removing Rounded Allen Bolts
 

The problem with these ones is they're set back into the footpeg mount so there's a good chance you'd be chopping into that before you got a decent slot into the top of the bolt.

Re: Removing Rounded Allen Bolts
 

How rounded is rounded?


If still has a bit of a socket put in the allen key apply a little turning pressure and hit / tap with a hammer.


If this don't work then as above slot or drill.

Re: Removing Rounded Allen Bolts
 

If you can hit in a torx bit without damaging the mounting that may give enough grip to undo the bolt.

Re: Removing Rounded Allen Bolts
 

I've tried all of the above, as Tom said they are recessed so you can't get in there with a dremmel.

I've tried the Torx bit technique and that didn't work, I couldn't really hammer it in far enough and don't want to be wielding a big hammer that close to the frame.

I think I am just going to have to hack the recessed section apart, it's going to be scrap anyway.

Re: Removing Rounded Allen Bolts
 

Hi
Try welding an old allen key into the rounded hole and then remove using a socket or spanner.
Cheers
Stuart

Re: Removing Rounded Allen Bolts
 

I don't have a welder