Removing Rounded Allen Bolts - SV650.org

L3nny · 07-11-16, 02:11 PM

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?

tom_e · 07-11-16, 02:25 PM

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.

L3nny · 07-11-16, 02:34 PM

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

Blapper · 07-11-16, 03:05 PM

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.

tom_e · 07-11-16, 03:22 PM

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.

shiftin_gear98 · 07-11-16, 03:30 PM

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.

Fen Tiger · 07-11-16, 04:01 PM

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

L3nny · 07-11-16, 04:09 PM

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.

Stuart42 · 07-11-16, 04:50 PM

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

L3nny · 07-11-16, 04:55 PM

Quote:

Originally Posted by Stuart42

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

I don't have a welder

07-11-16, 02:11 PM	#1
L3nny Member Mega Poster Join Date: May 2008 Location: MK Posts: 2,109	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? __________________ 2015 GS 1200 Adventure

07-11-16, 02:25 PM	#2
tom_e Member Join Date: Jun 2015 Posts: 438	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.

07-11-16, 02:34 PM	#3
L3nny Member Mega Poster Join Date: May 2008 Location: MK Posts: 2,109	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. __________________ 2015 GS 1200 Adventure

07-11-16, 03:05 PM	#4
Blapper Member Join Date: Jun 2016 Location: Rochester,Kent. Posts: 824	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.

07-11-16, 03:22 PM	#5
tom_e Member Join Date: Jun 2015 Posts: 438	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.

07-11-16, 03:30 PM	#6
shiftin_gear98 Member Join Date: Mar 2013 Location: At home Posts: 756	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.

07-11-16, 04:01 PM	#7
Fen Tiger Member Join Date: Oct 2014 Posts: 219	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.

07-11-16, 04:09 PM	#8
L3nny Member Mega Poster Join Date: May 2008 Location: MK Posts: 2,109	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. __________________ 2015 GS 1200 Adventure

07-11-16, 04:50 PM	#9
Stuart42 Member Join Date: Sep 2013 Location: Hampshire Posts: 165	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

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