Rear caliper allen key bolt stripped

Bones85 · June 26th, 2013, 09:25 AM

I was trying to get the rear brake caliper off on my bike and now one of the allen key bolts has been rounded out. When I insert the allen key, it just slides around and doesn't grip.

What should I do?

Thanks.

Lychee · June 26th, 2013, 09:30 AM

Quote:

Originally Posted by Bones85

I was trying to get the rear brake caliper off on my bike and now one of the allen key bolts has been rounded out. When I insert the allen key, it just slides around and doesn't grip.

What should I do?

Thanks.

Here are your options:
Bigger Allen key or comperable metric size or sae size
Hammer based Impact tool
Screw extractor
Ex out
Grind a slot into it and use a slotted screwdriver
Grind head completely off and use vice grips on remainder
Do Something with heat around the bolt?
Drill out with slightly smaller drill but and retap threads
Flat bed Tow to mechanic to have them do one of the above

cuong-nutz · June 26th, 2013, 09:31 AM

Drill it head completely out or get yourself a bolt extractor, EZ-out or the like.

indr · June 26th, 2013, 10:04 AM

Take a Torx bit that is one size too big to fit in the hole. Then spend a lot of time hammering it in there. Don't pound too hard. But, you want to make sure that it's in all the way (or very close to the bottom of the hole). If you don't, you're going to end up with a bigger hole when you go to turn it. I've done this twice (both times on the same bolt as yours) and it has worked every time.

You just have to take your time and make sure that the head of the torx bit is in as far as it'll go.

Bones85 · June 26th, 2013, 10:14 AM

Does anyone have two spare rear caliper bolts for sale? I believe the part number is 120CA0816

It's the two bolts that hold the caliper in place, not the two pins that go through the brake pads.

indr · June 26th, 2013, 10:46 AM

Cheaper to pick up matching metric bolts from Home Depot.

Bones85 · June 26th, 2013, 11:00 AM

I prefer staying with OEM bolts, especially since these are for the caliper. If anyone has a spare set I don't mind paying for them and the shipping, which should only cost like a dollar or two.

indr · June 26th, 2013, 11:07 AM

A bolt is a bolt. For the most part.

r6boater · June 26th, 2013, 12:22 PM

Mrcycles.Com has Them For $2.08 Each... Retail Is 2.98... Dealership Will Be Your Best Bet If You Insist On OEM.

indr · June 26th, 2013, 12:55 PM

Home Depot has em for $.75

Bones85 · June 29th, 2013, 11:36 AM

I bought a replacement bolt from Ace Hardware, but it's slightly thinner than the OEM bolt. When I screw it in it doesn't stop in the threads and ends up touching the rotor.

Is there anything I can do or am I just going to have to buy an OEM bolt?

indr · June 29th, 2013, 01:09 PM

You bought an SAE bolt. Get a metric bolt instead.

If the bolt is still too long, cut it off with a hacksaw or cutting blade.

Bones85 · June 29th, 2013, 01:30 PM

Quote:

Originally Posted by indr

You bought an SAE bolt. Get a metric bolt instead.

If the bolt is still too long, cut it off with a hacksaw or cutting blade.

I don't believe so. I took the OEM bolt into the store and an employee helped me find a match for it. The head on the bolt is the same (hex key) but the threaded part is skinnier than the OEM bolt so when I screw it into the caliper, it just keeps turning and doesn't stop like the OEM one.

indr · June 29th, 2013, 01:37 PM

It's not the same bolt. Was the bin labelled something like "M8x__" ?

Lowe's has a small selection of metric bolt. You're looking for a M8x36. The 36 is the length (in millimetres) of the bolt below the head. You should be able to get away with something as low as M8x34. But, it's better to get the next size up and cut off the excess.

rojoracing53 · June 29th, 2013, 01:38 PM

Quote:

Originally Posted by Bones85

I don't believe so. I took the OEM bolt into the store and an employee helped me find a match for it. The head on the bolt is the same (hex key) but the threaded part is skinnier than the OEM bolt so when I screw it into the caliper, it just keeps turning and doesn't stop like the OEM one.

Dude if it's skinnier then it's not the right bolt

Don't trust a hardware store employee to fine you anything metric, they normally know less then you

Bones85 · June 29th, 2013, 02:04 PM

Yes, it was the metric container. I'm not saying it's the exact same bolt because obviously it's not if it's thinner. I'm saying that it is a metric bolt though and not SAE.

Should I try Home Depot or Lowes then?

r6boater · June 30th, 2013, 12:20 PM

Quote:

Originally Posted by Bones85

Yes, it was the metric container. I'm not saying it's the exact same bolt because obviously it's not if it's thinner. I'm saying that it is a metric bolt though and not SAE.

Should I try Home Depot or Lowes then?

yes.
I know lowes has a display the you can run the bolt into to make sure you get the right pitch and diameter, then it is just a matter of getting the right length.

Bones85 · June 30th, 2013, 12:32 PM

I found the right one at Lowes. Thanks for the help.

Installed new front and rear tire and went for a ride and got caught in heavy rain/wind

I rode like a grandma and didn't have any problems but it was definitely a scary twenty miles.

June 26th, 2013, 09:25 AM	#1
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	Rear caliper allen key bolt stripped I was trying to get the rear brake caliper off on my bike and now one of the allen key bolts has been rounded out. When I insert the allen key, it just slides around and doesn't grip. What should I do? Thanks.

June 26th, 2013, 09:31 AM	#3
cuong-nutz RIP Alex Name: Cuong Location: Houston, TX Join Date: Apr 2011 Motorcycle(s): '10 250r, '09 265r Posts: A lot. Blog Entries: 2	Drill it head completely out or get yourself a bolt extractor, EZ-out or the like. __________________________________________________ HalfFast Racing Team Serving Greater Houston Area Riders:WFO Riders MotoHouston HPC CMRA Ride Smart Fastline Lone Star Track Days

June 26th, 2013, 12:22 PM	#9
r6boater ninjette.org member Name: Kurt Location: Knoxville Join Date: Oct 2012 Motorcycle(s): '04 R1 and '08 Ninja 250 Posts: 222	Mrcycles.Com has Them For $2.08 Each... Retail Is 2.98... Dealership Will Be Your Best Bet If You Insist On OEM. __________________________________________________ Check out this Ninja 250 roadracing youth---> TheDraik77 <--- My son

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June 26th, 2013, 10:04 AM	#4
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	Take a Torx bit that is one size too big to fit in the hole. Then spend a lot of time hammering it in there. Don't pound too hard. But, you want to make sure that it's in all the way (or very close to the bottom of the hole). If you don't, you're going to end up with a bigger hole when you go to turn it. I've done this twice (both times on the same bolt as yours) and it has worked every time. You just have to take your time and make sure that the head of the torx bit is in as far as it'll go.

June 26th, 2013, 10:14 AM	#5
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	Does anyone have two spare rear caliper bolts for sale? I believe the part number is 120CA0816 It's the two bolts that hold the caliper in place, not the two pins that go through the brake pads.

June 26th, 2013, 10:46 AM	#6
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	Cheaper to pick up matching metric bolts from Home Depot.

June 26th, 2013, 11:00 AM	#7
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	I prefer staying with OEM bolts, especially since these are for the caliper. If anyone has a spare set I don't mind paying for them and the shipping, which should only cost like a dollar or two.

June 26th, 2013, 11:07 AM	#8
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	A bolt is a bolt. For the most part.

June 26th, 2013, 12:55 PM	#10
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	Home Depot has em for $.75

June 29th, 2013, 11:36 AM	#11
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	I bought a replacement bolt from Ace Hardware, but it's slightly thinner than the OEM bolt. When I screw it in it doesn't stop in the threads and ends up touching the rotor. Is there anything I can do or am I just going to have to buy an OEM bolt?

June 29th, 2013, 01:09 PM	#12
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	You bought an SAE bolt. Get a metric bolt instead. If the bolt is still too long, cut it off with a hacksaw or cutting blade.

June 29th, 2013, 01:37 PM	#14
indr ninjette.org guru Name: . Location: . Join Date: Nov 2010 Motorcycle(s): . Posts: 331	It's not the same bolt. Was the bin labelled something like "M8x__" ? Lowe's has a small selection of metric bolt. You're looking for a M8x36. The 36 is the length (in millimetres) of the bolt below the head. You should be able to get away with something as low as M8x34. But, it's better to get the next size up and cut off the excess.

June 29th, 2013, 02:04 PM	#16
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	Yes, it was the metric container. I'm not saying it's the exact same bolt because obviously it's not if it's thinner. I'm saying that it is a metric bolt though and not SAE. Should I try Home Depot or Lowes then?

June 30th, 2013, 12:32 PM	#18
Bones85 ninjette.org member Name: Joe Location: Florida Join Date: Jan 2013 Motorcycle(s): 2009 Ninja 250R Posts: 206	I found the right one at Lowes. Thanks for the help. Installed new front and rear tire and went for a ride and got caught in heavy rain/wind I rode like a grandma and didn't have any problems but it was definitely a scary twenty miles.