Broken Allan key in my clutch weight.....Help

[b_doornenbal]

I was trying to pull my Cutler adjustable weights out of my 2008 M1000 and I broke off the allan key ( the little 5/64 one ) in the set screw at the top I tried to drill it out but my bits keep breaking... and the steel of the allan key is to hard for the bits I have. or my hand is not steady enough. My clutch puller is 5 hours away in storage so i have no way to pull the clutch to put it in a drill press.

I have one weight out, one set screw that is stripped ( I am getting an easy out on monday) and one with a broken allan key. So really i am screwed.

I made sure I heated the screws before trying to take them out as well....

Any ideas anyone has to help me out with this would be great.

 

[matm8snopro]

I was trying to pull my Cutler adjustable weights out of my 2008 M1000 and I broke off the allan key ( the little 5/64 one ) in the set screw at the top I tried to drill it out but my bits keep breaking... and the steel of the allan key is to hard for the bits I have. or my hand is not steady enough. My clutch puller is 5 hours away in storage so i have no way to pull the clutch to put it in a drill press.

I have one weight out, one set screw that is stripped ( I am getting an easy out on monday) and one with a broken allan key. So really i am screwed.

I made sure I heated the screws before trying to take them out as well....

Any ideas anyone has to help me out with this would be great.

If the easy out breaks, which they often do, try a good quality left hand drill bit like cobalt or something very strong. more times then not, the left hand drill bit will actually work better then an easy out. As for the broke allen key...good luck

 

[TROLLCAT]

Take punch about the same size as the allen screw small balpeen hammer rap the allen screw about 3 times this will loosen the threads & the seat of the allen screw then apply heat & left hand drill = rock & roll , try after striking the allen screw try a magnet to pull the broken piece out , I think the allen screws are metric good luck

 

[aamcustoms]

blow the piece out with air hose.. it will come

 

[m8welder]

Don't heat the screw you will only expand the screw making it even tighter.just put the heat to the clutch weight as much as possible to expand the thread hole

 

[canadian madman]

don't heat? i disagree...you need to heat the screw to unlock the locktite

 

[Polarblu]

heat it and then stick wax on it. it will get sucked into the threads and walla out it comes. Old machinist trick.

 

[glengine]

don't heat? i disagree...you need to heat the screw to unlock the locktite

What he is saying is try to heat the weight itself instead of the set screw. Will acheive same result in regards to loctite and should help to not expand set screw. But is tough to not heat both due to such a small area.

 

[M1K]

Same happened to me... used a cobalt drill bit and it chewed through the broken allen key like it wasn't even there.

 

[Rucky]

One thing I have to give to Polaris is the relation of weight and pin.... Their weight uses the pin as a bushing, and rotates on it, rather than the stupid set screw so that the pin rotates on the clutch. Sure you have to replace pins every now and again, but it's way less of a headache.