Stumped by flat battery and rounded allen key bolt

[Nat]

So today I went to start up my bike and the battery is totally flat. I figured I'd quickly whip off the seat and give the battery a charge. Turns out one of the allen keys was a little rounded and very stuck, so 10 mins of effort later and it's completely rounded and still totally stuck! Next I tried to roll start it, but no luck here either - the wheel just locks up and doesn't even turn the motor!

Does anyone have any advice? How can I start the bike? How can I deal with the bolt which I've totally rounded? As it is now, my bike's totally immobile all thanks to my zero skills at alley key undoing. :blink:

Thanks in advance,

[nodrog]

Try roll starting it in a higher gear, like 3rd or 4th.

[fokky]

Jump it,put leads to starter rather than battery.
Charge it in place..pull off one batt lead if possible.
What part Akl you in?

[Nat]

Thanks for the advice so far. I just tried roll starting it in 4th, still no luck. And with the rounded allen key bolt I can't even see the battery, much less try charging it. I am in Meadowbank

[fokky]

actually i take that back...if you have limited experience dont try to jump start it...........may get messy.

[Icemaestro]

not sure about 4th - I've always push started my bikes in 2nd gear...about 3 of them so far. As far as the bolt goes - CRC and then either 1) file/hacksaw a line in the top so you can use a flathead screwdriver, or 2) use a pair of pliers to turn it if possible, or 3) all of the above :-) (had to do all of these before!)

[neels]

Another option for damaged cap screws is if you have torx bits, find one that is just big enough to go into the damaged hex and hammer it in, then wind it out with a spanner. Works if it's not too tight for the splines on the torx bit to bite.

[ducatilover]

Don't charge it in place unless you have the battery disconnected, there's a potential risk of killing the reg/rec :facepalm:

Drill said bolt out, or weld another to it just to be interesting.

[Nat]

Unfortunately due to it being recessed I can't get to it with a hacksaw or with pliers. I'll give the torx a go now, otherwise I will get someone with some good skills and a steady hand to drill it out. Wish me luck!

[YellowDog]

Unfortunately due to it being recessed I can't get to it with a hacksaw or with pliers. I'll give the torx a go now, otherwise I will get someone with some good skills and a steady hand to drill it out. Wish me luck!

It shouldn't be that tough to get at the battery. If you remove all the panels that you can, this should reveal access to the terminals so that ypu can give it a jump.

FWIW: I bump start in third gear, but you do still need quite a hill to get enough momentum to pull the crank over. Perhaps if you can get someone to help you push it up a hill and then also help to get some speed up whilst attempting the bump.

[nodrog]

I've always push started my bikes in 2nd gear...about 3 of them so far.

your bikes have 3 2nd gears?

[Nat]

Another option for damaged cap screws is if you have torx bits, find one that is just big enough to go into the damaged hex and hammer it in, then wind it out with a spanner. Works if it's not too tight for the splines on the torx bit to bite.

Awesome! The torx bit did the job! I just hammered it in real good then used a spanner to turn it, just like you said. I would never've thought of using one of those, but it turns out to be perfect fit into the allen key bolts!

So now I have the battery out, it's going on charge out of the bike, and I'll be away laughing tomorrow morning!

Thanks heaps for you help everyone!

Nat

[Vinz0r]

When you push start your bike, you are getting a bit of momentum up before popping the clutch right?

[jellywrestler]

Awesome! The torx bit did the job! I just hammered it in real good then used a spanner to turn it, just like you said. I would never've thought of using one of those, but it turns out to be perfect fit into the allen key bolts!

So now I have the battery out, it's going on charge out of the bike, and I'll be away laughing tomorrow morning!

Thanks heaps for you help everyone!

Nat
now put a new bolt in so when it happens in the middle of nowhere it'll be easier