Broke Allen Key bit in one bolt. Please help !!!! :(

Hey everyone this is my first post here at 1199 Forum! I desperately need help!

I was trying to take off the exhaust (stock) and ceramic coat it. Everything was going on smoothly until I broke an Allen key in one of the bolts!

The bolt in particular is the lower one (closest to the ground) from the joint that connects the mufflers and the pipes. I can't even take a picture off it but I am hoping you all will understand what I am talking about.

I don't know what to do now I know I can't be harsh with it but I really wan't it out. Any help is more than appreciated!

Thanks

I'm guessing it broke pretty much flush with the head, so.....

- Lube spray

- Heat then cool

- More lube spray

- Then try and turn it backwards by hitting the stub with a centre punch, or pliers if you can grab it.

hsaeed said:

Hey everyone this is my first post here at 1199 Forum! I desperately need help!

I was trying to take off the exhaust (stock) and ceramic coat it. Everything was going on smoothly until I broke an Allen key in one of the bolts!

The bolt in particular is the lower one (closest to the ground) from the joint that connects the mufflers and the pipes. I can't even take a picture off it but I am hoping you all will understand what I am talking about.

I don't know what to do now I know I can't be harsh with it but I really wan't it out. Any help is more than appreciated!

Thanks

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Murphys Law. I hate that.

Its 10.30 at night here but I thought I would go out to see which one you are talking about. My old system is still in a box on the floor of the workshop. I think I know which one you mean.

If you cannot turn the head using pliers or vice grips then why don't you try removing the whole link pipe from the front cylinder and try to do the same with the rear and drop the mufflers and the one connector all out in one hit. Then you can get a good grip on the old allen bolt.

Plenty of WD40 and let is sit for a few hours.

There is always a way to get around it. Sometimes I come back the next day and with a fresh look you can see how to do it.

And be careful with the cylinder head studs ....don't fu#k those up.

Drill it out and get a cheap new y-pipe (the flange part) of ebay

center punch in the middle of the allen/hex thats stuck. Drill with a small bit in the center of it. gently hammer in the next drill bit size and pull it out with plyers. Liquid wrench prior to that may work.

Knocking it in the reverse direction with a center punch or screw driver should knock it loose or the start the bike to heat the bolt up. Good luck!

EnigmaRR said:

Knocking it in the reverse direction with a center punch or screw driver should knock it loose or the start the bike to beat the bolt up. Good luck!

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Starting the bike up and riding it might do the trick. I am always missing bolts that way. Sounds almost like a joke, but it's worth giving a try.

I have stick entire exhaust I sell u for 150 shipped

Thank you for all your responses!

Hey Everyone thank you for all the responses!

I'll take the bike out and ride it for a while and hope it comes out. I have put plenty of WD-40 on it to decrease friction. Let's see how it goes.

If this doesn't work I'll then move over to more extreme measures.

ecobully said:

Starting the bike up and riding it might do the trick. I am always missing bolts that way. Sounds almost like a joke, but it's worth giving a try.

Click to expand...

Lol, my thought was to start it also and let the bike do the work.

Heat bolt up and use strong magnet.