Stripped bolt head

[4unner4life]

I was trying to take my subframe off on my new but used yz 125 and the allen head bolt was stripped. I had read some other threads on it and decided to drill into the bolt and thread it to get a smaller bolt insde the allen head, but the tap broke and is stuck in the drilled bolt. :bang: WHY DO THEY PUT A RANDOM ALLEN HEAD BOLT ON THERE ANYWAYS?

But anyways any suggestions on getting the broken tap out? I have tried pliers and ripping it out and trying to move it around, but no luck.

This is my second stripped bolt in 3 months :| !

Thanks in advance

-Daniel

 

[ziptiedEXC]

If it is the long top subframe bolt, you could try drilling a small hole in the other end and using an easyout on it, not another tap.

 

[4unner4life]

its one of the lower small side bolts. The tap that is stuck in the drilled hole now is small. It is wedged in there. Ill try and take a picture of it.

 

[4unner4life]

here it is. That is a broken tap in the hole. Can't get it out.

 

[4unner4life]

heres a better one( I am new to posting pictures so give me a break)

<a href="http://img102.imageshack.us/my.php?image=dsc015347pj.jpg" target="_blank"><img src="http://img102.imageshack.us/img102/5569/dsc015347pj.th.jpg" border="0" alt="Free Image Hosting at www.ImageShack.us" /></a>


or

 

[4unner4life]

Update: I got the tap out and used a screw extractor and then i popped the bolt head and about 1/8 an inch off. I am trying to drill out the left overs, but it is not budging. Can anyone recommend a certain type of bit for metal?

 

[faceplantin]

The allen bolt is probably hardened steel. Use a sharp bit spinning slowly and use wd 40 or something to keep it cool. The key is to keep the rpms low and keep it cool. A drill doctor works great for sharpening bits. It will be slow going but you'll get it.

 

[sakirider]

So you still got of the tap in hole...thats super hard metal that will chew the **** outta any drill bit. If the bolt is screwed which i think it is try using a chisel and a hammer...make a grove or notch in the bolt head and use the chisel and hammer and hit it in the direction to out. Also try grinding a notch across the head of the bolt and using a big screw driver....use one which you can use a wrench on if you know the kind...that will work forsure. You can try left hand drill bits but i think those are useless.

 

[4unner4life]

Thats a good idea,grinding a notch. I would have done it but like i said the bolt head was torn off by the screw extractor. I am going to go get some new bits tomorow and try to get this thing off. I will slow down my rpms and keep it cool. Ill let you know how it goes tomorow

Thanks for your help guys

 

[sakirider]

IS there any space at all from the flush bolt to the tap pieces...if so you need easy outs....they work awesome.

 

[faceplantin]

Good luck

Sakirider is right. :worship: The notch thing works great. It'll even work on a bolt shank thats flush. Use a dremel with a grinding wheel.

 

[sakirider]

Cheers...

 

[bigdaddyadd]

weld it

when I get an allen head round off on me I generally get an old key that I dont mind sacrificincing. stick it in the whole thats left and put a couple of small tacks on it. Often the little bit of heat alone is enough to get the thing moving.

 

[4unner4life]

I will have to get a welder one of these days. Right now i think my only option is to drill it out, but I am not making any progress with that because the metal is just to hard. There is a few scraps of the tap still left in there. I tried drilling from the other side but there was to much of an angle and started grinding off part of frame. OOPS

 

[4unner4life]

BUMP! How can i get the rest of the tap out. Drilling ain't working. I have tried hammering it from side to side to loosen it put it just isnt breaking loose. I can move from side to side now but cant get it out. The Subframe hole is looking like a big mess now. What is my next option seeing how drilling is not working.

 

[faceplantin]

The bolt head snapped off so the subframe should be free of the frame? right? Can you remove the whole sub from the bike? If so, drill it on a drill press or take it to a machine shop. Sounds like you will end up having to weld in a new thread insert when your done.

Allen heads are tough. You have to use a good wrench that is not rounded at all and consider using a little heat when loosening. You might be over torquing them.

 

[4unner4life]

Well the head fell of but the bolt "shaft" still goes all the way through and the subframe piece goes in between two main frame pieces, so i cant take it out unless i have the bolt all the way out.

 

[faceplantin]

Man what a jam.

Can you get a hacksaw blade or sawsall between the pieces to cut through the bolt?

 

[4unner4life]

After about 30 minutes of hammering the small piece of tap side to side, I decided to hose the hole down to get out all the metal shavings and what do you know t he tap piece comes out. Well i actually didnt see it come out then, but after i rode it around the yard for a second and saw it wasnt there anymore. So tomorow im going to start drilling the hole again. It should all go smooth now because all the tap pieces are out but i will let yall know how it goes.