Adventure Bike Rider Forum

Not sure if there is an answer to this one, but whilst trying to take off the handguards on my bike using a Hex Allen key , the head snapped off in the screw and although I can get a wrench on the nut on the back, because I now can't get a Allen key into the screw head the damn thing won't loosen and therefore I can't get the handguard off?

Anyone know of any tools or techniques to somehow get the Hex head out of the screwhead?

i have a set like this:

Easy Out

Works very well

Is the Allen key head countersunk?
If not I use grips and turn it with them
Remove the nut first

Ouch! First thing is to soak the threads at the back with WD40 or similar so that when you get things moving, it is loose. I am assuming you have no access with mole grips or similar to the head? Some first thoughts...

Drilling the allen key out will be hard, as they are tough old sods, if you can, start small bit and keep going up a size in drill bit. Or cut a line across the top with a Dremel to hold a screwdriver bit?

If you have a lot of thread showing at the back, grip that with mole grips and undo the nut, but it does need the pre-lube treatment to work IME :whistle: Cut the nut off at the back with a Dremel not the bolt, but the nut, so it comes away.

Good luck

I am going to be a bit technical here if the Allen key is snapped in the bolt and you can get at the nut it's easy the bolt is fucked.
So cut the nut of and throw the bolt away and fit a new one with a bit of copper grease on it

HTH

Sounds like a job for a dremel disc cutter

I don't get it, if the head snapped off why doesn't the bolt pull through, or wind through, the back :blink: Anyway as per the two previous posts, cut the nut off (thumbs)

Know anyone with a welder?

Tack weld a nut or hex bar onto what you can see then use a socket to get it out. You'll lose the screw but you'll be sorted

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DaveCon wrote:I don't get it, if the head snapped off why doesn't the bolt pull through, or wind through, the back :blink: Anyway as per the two previous posts, cut the nut off (thumbs)

I think its the Allen key that has snapped off not the bolt head.......

Already answered but if its stiff enough to snap an allen key, then its not coming off easily so best to cut the nut off and replace both the nut and bolt..

Thanks for all the advice, having tried to drill it out and the drill couldn't make a dent in it, not being able to get a grip of the round screw head due to the plastic cover if handguard and having tried WD40 to loosen everything up and it won't budge, I am going to try and cut it off as suggested, as can't see any other way to get it out.

Thanks guys