K11 Owners Group

gladstone

Anyone have any ideas about how to remove a seized front brake lever retaining pin? The head of the Allen bolt has rounded off, and looking at its shape drilling out doesn't look like an option.

Any help appreciated.

Cheers
_________________
1993 K1100LT (x2!)
1998 R1100R - gone
1994 R1100GS - gone
1990 K100RS 16V - gone

Inge K. · Posted: Tue Jun 21, 2011 5:34 am Post subject:

First off all I would removed the master from the bike...to a vice, if not allready done.
Then drilled the hole in the bolt a bit deeper, to accept a conical extractor.

Start with same diameter as the allen only to get the center, then one with a couple of mm smaller diameter...
because the screw is trapped down under the head, to accept a bushing.
Soak the screw overnight with penetrating oil.

If it`s still is stubborn, try to add some heat to the lever...the threads is in the lever and not the master housing.

On the other hand I don`t see any problem with drilling it out (less time consume), prefeerably in a drill stand, starting with a small drill bit.
Worst thing that can happen is that you need a new lever.

Inge K.

Flying Duck · Posted: Tue Jun 21, 2011 6:46 am Post subject:

Sometimes you can pound a Torx bit into a stripped Allen head.
_________________
93 LT (x2)
94 RS
86-97 K75F(K75/100/1100 Frankenbrick)
86 K75C w/paralever, hi perf cams,TURBO!
91 & 92 K75Ss
91 K1
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gladstone · Posted: Tue Jun 21, 2011 8:08 am Post subject:

Thanks guys; I'll go with drill and extrator. I tried to use a torx bit to remove a snapped exhaust stud and suffice to say both are still in place - the head of the torx snapped off in the stud.

I'll also try to remove from the bar, although I take it that's a tank-off operation as I want to save the working heated grips.

Thanks again.

Cheers
_________________
1993 K1100LT (x2!)
1998 R1100R - gone
1994 R1100GS - gone
1990 K100RS 16V - gone

gladstone · Posted: Tue Jun 21, 2011 3:47 pm Post subject:

Managed to get the bolt out by drilling out with the master cylinder still on the bike - result!

The leak was a result of a rebuild using the old piston - have now honed and rebuilt with a new piston.

I'll pinch the brake lever off my spare LT and road-test tomorrow.

Thanks again.

Cheers
_________________
1993 K1100LT (x2!)
1998 R1100R - gone
1994 R1100GS - gone
1990 K100RS 16V - gone