Stuck Alternator Bolt

[GSTom]

I need to replace the "monkey nuts" rubber cushions in the alternator drive (1988 K100LT). I have disassembled things to access the alternator but the top mounting bolt is frozen and won't break loose. I used a "ball and socket" allen head wrench and the ball is now broken off in the head of the bolt. I do not want to remove the wiring and box above the alternator to get to the frozen bolt with vice grips, but.... Any suggestions from the collective K-bike mechanic community?
Thanks in advance GS Tom:scratch

[chuck_donahue]

I need to replace the "monkey nuts" rubber cushions in the alternator drive (1988 K100LT). I have disassembled things to access the alternator but the top mounting bolt is frozen and won't break loose. I used a "ball and socket" allen head wrench and the ball is now broken off in the head of the bolt. I do not want to remove the wiring and box above the alternator to get to the frozen bolt with vice grips, but.... Any suggestions from the collective K-bike mechanic community?
Thanks in advance GS Tom:scratch

Sorry to hear you are having a bad day.
I would try to get the ball out of the allen. it went in it should come out, then use a good quality allen give it a hard wack not steady hard pressure. If there is room put a extention on the allen wrench.

I use a set that goes on a ratchet, they work great.
Lastly don't use cheap tools. they end up costing you in skin, time, and fastners.

Sit there, have a beer, look at it, it will come to you.

If that dosn't work .... well you can always remove the wiring.

chuck

chuck
:usa

[breyfogle]

I need to replace the "monkey nuts" <snip> I do not want to remove the wiring and box above the alternator to get to the frozen bolt with vice grips, but.... Any suggestions

A shop mechanic once told me that it is almost always faster & easier to take the time to remove all the parts that may be in the way of reaching whatever bit you are working on. It was, IMHO, good advice.

Access to the alternator is MUCH easier if you remove the computer, storage tray and battery without the need to use ball-end allen wrenches.

[lostboy]

Can you get at the side of the bolt head with a chisel? All you need is to get the bolt broken loose.

[GSTom]

I went to Harbor freight and bought a set of Bolt Extraction sockets. The metric size did not work on the round bolt head, so after another trip to "the Harbor" I got a set of SAE extractors. With a small amount of tapping with a light hammer, I was able to drive the closest sized SAE extractor on and.. Voila', problem solved.

[warredon]

Way to go! I saw those when I was in Harbor Freight the other day and wondered how well they worked.

[PGlaves]

Way to go! I saw those when I was in Harbor Freight the other day and wondered how well they worked.

The couple of times I needed to use them they worked great. Recommended!

[chuck_donahue]

I went to Harbor freight and bought a set of Bolt Extraction sockets. The metric size did not work on the round bolt head, so after another trip to "the Harbor" I got a set of SAE extractors. With a small amount of tapping with a light hammer, I was able to drive the closest sized SAE extractor on and.. Voila', problem solved.

Now don't use those ball end allens to break folts free anymore.

[breyfogle]

Now don't use those ball end allens to break folts free anymore.
+1 I have a set of long reach, ball end, 3/8 inch drive, allen wrenches that are great for reaching awkward locations but they are strictly low torque tools. They seem to work best for the 3, 4, 5 mm sizes that don't generally need much torque. Any size larger is usually for a bolt that requires more torque than the ball-end wrench can apply without buggering up the hex head socket.