Removal of front discs - 2004 1200

[Neil A]

Well, I haven't asked a question for a while....

2004 R1200GS. Went to change the front discs last weekend, but couldn't find a bit to fit the button-head bolts that secure the discs to the hub. I squinted at them long and hard with my weary old eyes and a torch and they are definitely hex Allen head bolts, not Torx, but it's a 55k bike and I'm not the first owner, so lord knows if they are the original bolts. Plus, there is no Torx key in my set that fits either (I tried, just in case I am more mad/blind than I realised).

The smaller size Allen key that would fit in was too loose to try taking them out. It would have turned the middle out of the heads. All were the same. I want to re-use the bolts, as I am a tightwad, so I don't want to try "aggressive" removal unless I have to. I got some of the right threadlock, so I could reuse them after a clean-up. Plus, it'll take ages to butcher them out.

Any thoughts? What size/type of key should fit, if they are the original bolts?

Thanks for any help and sod off if you are going to take the piss, unless it's entertaining, in which case, crack on...

Neil

 

[bisbee]

Torx T40 on my 2006

 

[Neil A]

Torx T40 on my 2006

Thanks, I'll go back and recheck, but I definitely have one of them, so I must have tried it

I'd have thought

Mind you, I have noticed a terrible smell of wee recently

 

[Beemerman59]

The screw heads may need a thorough clean out for a good fit - whether they're torx or someone has changed them to hex over time. I have some bolts that the hex head tools from my old K bikes toolkit fit far better than any other Allen key I have - are they slightly different dimensions?

 

[Bendy toy]

Bodge them off and fit new bolts.

I have a 5mm hex Allen key as part of a bicycle tool kit that fits brake parts on my bicycle. So what(?) 5mm is 5mm, but the 5mm hex key I use for everything else is slightly too big for those bicycle bolts.

 

[retardedignition]

New Bolts - it ain't worth saving the cash.

I changed mine last night, bolts and wavy washers from motoworks, discs from GS Shop, bike stops a treat and I can sleep at night.

Regards

Rob

 

[Bendy toy]

If the bolt hole are open at the back soak them with a good penetrating oil. Then use an impact driver to loosen them. One thump tighter before untigtening can help break the grip. Stubborn bolts can be shifted by arc welding onto the bolt head. The localised extreme heat breaks corrosion and threadlock so the bolts come off easily. Don't fill the socket of course!
A heat gun is pointless on alloy wheels because there is just too much metal mass to get hot enough to have a useful effect.

 

[Neil A]

New Bolts - it ain't worth saving the cash..... bolts and wavy washers from motoworks

I have done that now - £37, incl delivery. A bit of a waste, if it had been avoidable

 

[Neil A]

But thanks to everyone who took the trouble to reply

 

[retardedignition]

Neil

I did notice the paint on the bolt heads is quite soft, so I'm going to touch it in with some zinc rich paint or lacquer now I've fitted the discs.

Regards

Rob
Trending towards OCD!

 

[Neil A]

I have done that now - £37, incl delivery. A bit of a waste, if it had been avoidable

BAH! Motorworks out of stock!

 

[retardedignition]

I've been checking out some wheel bits and pieces against motorworks and my local dealer, to be honest they were so close in price it wasn't worth worrying about. They could post them to you if your nearest dealer is too far.

Just a thought!

 

[EURTRAF]

Heat the bolts up with a paint stripping heat gun and they come out very easily, then run a tap down the hole when cool to clean out the thread lock form the thread.

S

 

[Bendy toy]

Heat the bolts up with a paint stripping heat gun and they come out very easily, then run a tap down the hole when cool to clean out the thread lock form the thread.

S

I could not get enough local heat to work like this, but arc weld onto the bolt head worked well and did not damage the paint. The bolts were of course scrap. An alternative to new bolts (if they were not arc welded) could be to have them zinc plated.