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Discussion Starter #1
I managed to snap the head off an allen key.

Best way to get it out.
I cant use a drill (no enough space)
Please dont say giant magnet unless you have one that you will send to me.

Third pic is what it should look like



 

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Basically, you have to destroy the bolt to do it. Get a really good sharp punch and come in from the side of the hex at an angle. You may have to slot the bolt and remove it with a flat head screwdriver.

For the future, if you are going to buy ball end Allen keys make sure you buy very high quality ones
 

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Discussion Starter #3
Best way to slot it. Its pretty tight in there.

Yeah i caught a lot of flake from the room mate. What really stings is that I have 3 other sets of allen keys, those where just the closest
 

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A dremel. You could also use just the blade of a hacksaw. You'll want to protect the plastics against slips if you go with that method
 

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Discussion Starter #6
super glue doesnt work, i tried...didnt try with loctite though.

a dremel might be in my future
 

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That's an R6, go to the Yamaha forums for help.






jk. Yeah, a dremel multi tool is handy to have, I've used mine about half a dozen times to help me out of jams or sand down parts. Is that a size 3 or 4 hex? That is needlessly tiny.
 

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Cut a groove in the head of the bolt and back it out with a flat head screwdriver. If you try to use force you could possibility damage the fairing.

Wibbly mentioned it above... Have you tried using a magnet?
 

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Haven't you tried to get a hold on the edge of the bolt with some pliers?

In the worst case you can drill a straight groove on the bolt's head with a saw (carefull with the fairing) and then remove it with a flat head screwdriver.
 

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Dremel tool + flat head screwdriver.

If you feel fancy, JB Weld + Torx bit = fill in the allen slot with jbweld and try to jam a slightly large torx bit and pray it will work.

Alternatively, remove the bolt of the fairing mount on the frame (which is very accessible), remove the other fairing bolt(s), remove the fairing and turn the allen bolt from inside the fairing.
 

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Rinonz second idea is the winner here. Take the fairing off and leave the bracket attached. It should be easy from there. Get the piece of Allen key out with a punch and then drill the top of the bolt off. Easy.

Don't drill it with the Allen key still in there. You'll get nowhere
 

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I guess I'm a little confused by what you're asking? You broke the end off the allen key. Is the bolt head now stripped? Are you saying that the end of the allen key is stuck inside the bolt head? (sorry it's early for me) if it is, take a pick tool and punch in between the broken piece and the bolt, that should loosen it up enough to fall out. Once you get that out try using a shorter one the same size horizontally to get leverage on the bolt. The problem with using those swivel and angled tips is that you really need to firmly press them down because there isn't as much contact being made from the round shaped hex. If the bolt isn't badly stripped, you can use a punch and a torx bit by tapping it on. Use an extension with a ratchet and make sure it's pointing straight up. If the bolt is fucked up beyond all repair, you can cut a slot into it, but if it's recessed you're risking cutting into bodywork. Sometimes some penetrating oil can help a little bit when trying these things too.
 

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Discussion Starter #13
That's an R6, go to the Yamaha forums for help.




jk. Yeah, a dremel multi tool is handy to have, I've used mine about half a dozen times to help me out of jams or sand down parts. Is that a size 3 or 4 hex? That is needlessly tiny.
Ha, Honda guys are more helpful.
Size 4...yamaha's....

Alternatively, remove the bolt of the fairing mount on the frame (which is very accessible), remove the other fairing bolt(s), remove the fairing and turn the allen bolt from inside the fairing.
This is what happened. Coming from my last bike this didnt even occur to me. To mad i snapped the allen key in the first place.

Don't drill it with the Allen key still in there. You'll get nowhere
This, other suggested this but unless you have some super strong bits you are going to just destroy them trying to drill a allen key...drill bit vs hardened steel, the drill bit is going to lose.
 
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