Help with drilling out hugger bolt!

andirsv1 · Mar 7, 2009

Morning all, some of you may know, one of the allen headed bolts securing the hugger have sheared off leaving the threaded part in the hole! The hugger now won't sit right as needs all 4 to seat properly!

The hole in question is the one directly below the battery holder so is it a case of stripping the bike down and removing the battery box to get a straight drill at it?? Also what drill bit should i use??? Never done this before so a little apprehensive about doing it.........

uke

Olek · Mar 7, 2009

hi andi, may be best to strip out the battery box to ensure a straight shot at it, start off with an 1/8 bit (couple of mil thick) Then once you have that in take it out with a slightly larger bit before trying to get your reverse tap in. sometimes if you get the hole straight and take it out little by little the remains on the bolt will simply crumble :doug( however if the hole is not straight then you risk damaging the thread inside the hole which will lead to you having to re-tap the hole:jack. like i said use an 1/8th bit fist, then if its a 6m hole use a 4m bit to enable you to get your extractor in. Hope that helps bud. and good luck... Remember patience is all important:thumbup

andirsv1 · Mar 7, 2009

Thanks Olek.........I'll get the bike stripped today and make a go of it tomorrow.....fingers crossed it goes smoothly.......:thumbup

amb67 · Mar 7, 2009

No need to Andi, just let the bottom shock bolt go and the swing arm drops down enough to get a regular drill and bit in to remove the sheared bolt.

I bought a Heli Coil set off Ebay for around £8 delivered, seem to remember it was a 5mm kit.

Be careful when drilling that you don't go off centre, you could end up with a rather large hole. But hey if this does happen it can easily be repaired, it's not as if this bolt is a load bearing bolt, is it?

Let us know if you get stuck, I had this scenario over Christmas when all bar one sheared off on me.

Olek · Mar 7, 2009

Ill pm you my number, any probs giz a bell . as i work in a bodyshop and this **** is my bread and butter. Shame you are so far away otherwise i would come round and do it for you....

superninj · Mar 7, 2009

Don't worry about it mate, just take your time to drill straight and even if you do fudge it up you can use a Heli Coil kit. I had to replace a thread for the coolant drain on my ktm 125 that the previous owner fooked the thread up on and it worked like a dream.

I know its a pain as i have snapped off 3 of the heads removing my hugger to lacquer my carbon hugger!:rant

Good luck :thumbup

Fazza · Mar 7, 2009

Hey Olek, I don't know if you saw my earlier post but I've got a sheared swingarm bolt too,

I've had a try at drilling it but have made a bit of a mess, the bit always seems to slip from the point where I'm trying to drill.

Any tips into preventing this or just up the road if you fancy popping over? I'll buy you a pint

superninj · Mar 7, 2009

Fazza said:
Hey Olek, I don't know if you saw my earlier post but I've got a sheared swingarm bolt too,

I've had a try at drilling it but have made a bit of a mess, the bit always seems to slip from the point where I'm trying to drill.

Any tips into preventing this or just up the road if you fancy popping over? I'll buy you a pint

The bolts in attaching my hugger are aluminum, what are yours? have you tried using a centre punch to get a starting point and like some of the others have said us a really small drill to start with.

Fazza · Mar 7, 2009

It's a bolt that holds the retainer for the brake cable and speed sensor cable on the right hand side. I think it's steel. I'll try a centre punch but it's in an awkward position

andirsv1 · Mar 7, 2009

amb67 said:
No need to Andi, just let the bottom shock bolt go and the swing arm drops down enough to get a regular drill and bit in to remove the sheared bolt.

That sounds good Alan!! This may be a f*ckin stupid question but if i remove the bottom shock bolt and the swing arm drops, how do you maintain the height of the subframe, seat unit etc in order to create the space to get the drill in, won't the wholerear end drop???? Does that make sense buddy??????????

amb67 · Mar 7, 2009

andirsv said:
That sounds good Alan!! This may be a f*ckin stupid question but if i remove the bottom shock bolt and the swing arm drops, how do you maintain the height of the subframe, seat unit etc in order to create the space to get the drill in, won't the wholerear end drop???? Does that make sense buddy??????????

You need to support the weight of the bike via the main frame, this can be done using an Abba type stand, a jack under the engine, strung from the rafters, whatever you decide.

Should have made that clear in my first post, sorry!!

I use 2 axle stands and a bar that goes through the frame, works a treat and cost me £10 for the axle stands off Ebay.

andirsv1 · Mar 7, 2009

Ah.....got you mate...:thumbup..........axle stands it is then...:thumbup

Out of interest, you dont' know the diameter of the bar you used do you?? or will any diameter do as long as it goes through the frame??

:thumbup

amb67 · Mar 7, 2009

Mines actually a 3/8 drive extra long socket extension bar.

But any diameter bar that will go through the hole is fine.

You got any replacement bolts yet?

If they are M5 I have some lovely polished head ones I can send you!!

Let me know what size you have and I'll see what I have in my stainless steel bolt tin.

Alan

andirsv1 · Mar 7, 2009

amb67 said:
Mines actually a 3/8 drive extra long socket extension bar.

But any diameter bar that will go through the hole is fine.

You got any replacement bolts yet?

If they are M5 I have some lovely polished head ones I can send you!!

Let me know what size you have and I'll see what I have in my stainless steel bolt tin.

Alan

Thanks buddy....:thumbup top man, to be honest Alan mate, i've no idea what size they are, they seem to be the originals though if that helps????

amb67 · Mar 7, 2009

Yeah, should be M5x 16mm.

Let me know if you want them posting up to you with that clutch screw.

You'll need a hacksaw to cut them down to size as I bought extra long ones so I could use them elsewhere on the bike.

Alan

superyellow · Mar 7, 2009

my buddy removed a shaved off/glazed bar end bolt from my suzuki with a regular drill bit and a rechargeable Makita drill($400) in 10 seconds and I was likje WTF? I spent 1 hour and couldn't get it out with my piss of **** Black and drill high speed drill..

andirsv1 · Mar 8, 2009

amb67 said:
Yeah, should be M5x 16mm.

Let me know if you want them posting up to you with that clutch screw.

You'll need a hacksaw to cut them down to size as I bought extra long ones so I could use them elsewhere on the bike.

Alan

Alan mate....that would be great if you don't mind??? I'll send you some cash via paypal, or case of beer etc.....whatever you fancy mate.

Top man...........thanks again...................:thumbup

amb67 · Mar 8, 2009

andirsv said:
Alan mate....that would be great if you don't mind??? I'll send you some cash via paypal, or case of beer etc.....whatever you fancy mate.

Top man...........thanks again...................:thumbup

No worries Andi, they'll go out in the post first thing in the morning. (I don't want your money)

I've put in that small clutch screw we talked about on the other thread, four M5 x 20mm polished stainless steel button head screws with four plastic washers so you don't damage the finish on your hugger.

Should be with you Wednesday mate.

andirsv1 · Mar 8, 2009

amb67 said:
No worries Andi, they'll go out in the post first thing in the morning. (I don't want your money)

I've put in that small clutch screw we talked about on the other thread, four M5 x 20mm polished stainless steel button head screws with four plastic washers so you don't damage the finish on your hugger.

Should be with you Wednesday mate.

Than you very much Alan, your a gentleman.........:thumbup

I'll buy you a good few beers when we meet up.

Top man...............:thumbup

Help with drilling out hugger bolt!

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