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Thread: Nutz - Smallest wrench I own, wrong time of year, need mechanical advice

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  1. #1
    Western NY Rider drubery's Avatar
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    Nutz - Smallest wrench I own, wrong time of year, need mechanical advice

    First, my heart goes out to those in Boston..!

    Now to my very minor problem, at least in the grand scheme of life. Well this could have happened on the road, so I am fortunate it did not. Right clip on seemed loose on my 2007 K1200GT and I thought it was the bolt that goes into the handlebar, it has a rubber grommet it goes through and helps prevent the controls from rotating. It screws right into the forged aluminum handlebar. Yes, I snapped it right off with the smallest wrench I own.

    I have big white zip tie on there at the moment and I am weighing whether or not I should ride it like this the 5 miles to the dealer? I am also wondering how they are going to remove what is left. Am I sunk and looking at buying a new handlebar? ($665!)

    Any words of encouragement at an extremely busy time of year for our dealers would be appreciated. Unfortunately so would blatant honesty.

    Thanks,

    -Dennis

    nutz.jpg
    2013 BMW K1600GT - Montego Blue Metallic
    2007 BMW K1200GT - Graphite (traded)
    2004 R1150RS - Pacific Blue (sold )
    Dennis BMWMOA 150423 FingerLakes BMW Club 396 IBA 50178

  2. #2
    John. jstrube's Avatar
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    If you remove the stuff over the bolt, can you get purchase on it with vice grips? I've found that very tight vice grips can often remove a broken bolt. If not, they will probably drill it & use an ez-out.

    I hope you were tightening when it broke. I would put some penetrant on it to ease removal just in case there is some corrosion in there.

    Doesn't look like that is anything mission critical, so I would probably ride it 5 miles.

    If the dealer can't do it, I would try a machine shop. They deal with that sort of thing on a regular basis.
    John.

  3. #3
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    Cool Easy out.

    An easy out or similar device will get the piece out.
    2009 K1300GT Blue
    1983 Honda CB1100F Blue
    1980 Honda CBX-A Black
    Blue or Black is Fastest

  4. #4
    Western NY Rider drubery's Avatar
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    Thanks guys.. An easy-out will have to be the call as no portion protruding underneath the grommet to get purchase. Still not sure on the ride, I am sure I will have to leave it for a long time as they are racked up over there! I am lucky one of the guys is really well known in motorcycle circles around here, so if it can be removed with an easy-out he might have the touch. Just not sure if it's a look at it when I bring it in and a shake of the head and I'll knock this out in 5 minutes deal or I am without the bike for two weeks. Jonesing up here in the great white north!
    2013 BMW K1600GT - Montego Blue Metallic
    2007 BMW K1200GT - Graphite (traded)
    2004 R1150RS - Pacific Blue (sold )
    Dennis BMWMOA 150423 FingerLakes BMW Club 396 IBA 50178

  5. #5
    Back in the Saddle mcmxcivrs's Avatar
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    An easyout should work fine, just be very careful. Make sure you drill the hole as centered as possible, you may need to file the end of the broken bolt flat to get the drill to not wander. Make a good center punch mark to ensure the drill starts in the correct spot, then drill with a very small bit first, going to the correct size for the easyout with a second drill (you may be able to drill it with the proper size firts for a small size easyout/bolt). Once you have the hole, try the easyout carefully, DO NOT FORCE IT if the bolt does not move easily. If you break either a drill bit or the easyout in the bolt, you may well end up having to replace the bar before you can get any of it out. I would expect though that once drilled, it will come out easily with little force as you likely twisted it off due to excess tightening which would mean the threaded part is not bottomed out or siezed in. If it is bottomed or siezed, then it may not want to come out at all, at which point you may have to drill it out completly and have a thread repair insert put in. In any case, there should be no reason for having to replace the bars.

    Good luck, take your time and it should be fine.
    Ed Miller, Calgary, AB
    2008 K1200GT, 2009 F800GS
    I can't wait to retire and have a fixed income. The one I have now is always broke.

  6. #6
    Western NY Rider drubery's Avatar
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    M5x10

    So there are two identical bolts one on the right and one on the left which basically prevent your controls from rotating and also from sliding out. The one on the right is the one I snapped off just below the surface. Going to have to trailer the bike to the shop and have them remove the controls. Then I'll have to pick up the bars and take them to a machinist and cross my fingers, but my gut tells me they'll end up drilling it out and putting an M5x10 plug in. If money were no object I would trade it in on a new GT, still doing this:
    2013 BMW K1600GT - Montego Blue Metallic
    2007 BMW K1200GT - Graphite (traded)
    2004 R1150RS - Pacific Blue (sold )
    Dennis BMWMOA 150423 FingerLakes BMW Club 396 IBA 50178

  7. #7
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    FWIW, if I had to do this myself I'd just drill the whole thing out before messing with an easy out. Those things are extremely brittle and snap off readily with little force and no warning- especially in smaller sizes. They're fine on larger stuff where you can get heat on stuck bolts but more likely to just cause trouble on small stuff....

    Stainless bolts don't drill easily- a good sharp set of proper alloy is needed...

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