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[courter]

I was working on my wife's bike and broke off the ball end of an Allen wrench in one of the primary inspection cover screws.  It went in tight, and then just broke off.  Must be I don't know my own strength!  Now I've got a small hexagon ball stuck in there! 

Any ideas how to get it out?  I can't reach it with any kind of pliers, and I can't get another wrench in behind it to take it out and replace it.  Will heat help?  Don't want to damage the aluminum around it.

[rednectum]

take it for a ride, it may vibrate out!

[The Mysterious Q!]

Well get a drift punch and at a slight angle tap the piece counter clockwise or the way that would loosen the bolt. It probably is jammed in the allen socket of the bolt when you tightened it. It should fall out when it moves back a little. Heat won't help in this situation unless your looking to loosen the bolt as well. Later,Q

[murphy]

You could drill it out.... if you have a steady hand!

[Hugh Janis]

does the allen nut stick out enough to get vise grips on it?  You'd have to replace the marred nut but it's only $ eleventy seven dollars at HD....

[courter]

No, it doesn't stick out at all.  Also, the screw is flush -- if it was a regular socket head cap screw it would be a no brainer.  I think I'll drill out the screw and replace it.  Not really worth too much trouble (unless I miss and goof up the primary cover)...

[The Mysterious Q!]

No, it doesn't stick out at all.  Also, the screw is flush -- if it was a regular socket head cap screw it would be a no brainer.  I think I'll drill out the screw and replace it.  Not really worth too much trouble (unless I miss and goof up the primary cover)...

Being that the allen wrench is hardened stell start with a tiny bit and work up in size. Go slow and keep the bit cool. Keep a cup of oil or water and dip the bit in when it starts getting hot.  Q

[SPIDERMAN]

take it for a ride, it may vibrate out!

Depending on if there's a need to get the damn thing out in a hurry or not, this is actually the best way  Right now, the corners of the broken piece are biting into the socket head. After some miles (no idea how many)  they will back off and the piece will fall out.

Unless you put locktite on it   

B B

[murphy]

The amount of coordination involved to drill straight is going to be intense…. I’d save the beer till after the job’s done!

Might be an idea to put it up on a jack or center stand and make some kind of support to steady the drill….

Glad it’s you and not me….

Good luck!!!

[Gettinold]

I love these kind of challenges.Try riding the bike and bringing it up to temperture. Then sray it with a can of freon and blow it with compressed air @ the same time.  HOT COLD HOT COLD.............. IT WILL FALL OUT

Good luck. 

         Dave

[spydglide]

a good penetrating oil never hurts when trying to unstick and two metal surfaces.  My approach is to try everything that won't damage anything else until something works.  SNAFU, baby, SNAFU!  har!  spyder

[HogBreath]

I've heard Monica Lowenski could suck the chrome off a bumper.......I'm just wondering..

[Hoist!]

I love these kind of challenges.Try riding the bike and bringing it up to temperture. Then sray it with a can of freon and blow it with compressed air @ the same time.  HOT COLD HOT COLD.............. IT WILL FALL OUT

Good luck. 

         Dave

If you're using Refrigerant to cool it, make sure you turn the can upside down to release liquid Refrigerant. That will evaporate immediately and freeze the area you want to cool. If you hold the can right side up, you'll release vapor, which won't provide any cooling effect.

Hoist!

[Midnight Rider]

If the bolt is already tight, I'd just ride it and see if it falls out on it's own...I'd save the drilling as a last resort.  One slip, and you've messed up a nice shiney piece...

[RedFXR2]

If you've got one, or can borrow one, you might try a electric etching pencil.  You've seen them, those things used to scribe marks, names, whatever on metals or plastics.  It has a very rapidly vibrating small, hard tip but is easy to control.  Might be able to "massage" it loose.