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Old 02-11-2009, 01:22 PM   #10
tmex OP
Beastly Adventurer
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Joined: Apr 2006
Location: NorCal
Oddometer: 2,039
All good points single-track. I find drilling the bolts the hardest part. Cobalt bits seem to work the best, and a drill press is essential IMO. Take your time and use common sense, and you won't break too many bits. I actually prefer a 3/32" inch bit to the 1/16" since the bit seems much more robust. Also do not drill too close to the top of the bolt since that can weaken the bolt. Parts that are removed often and used with a clip, such as the oil fill plug, should have fewer twists since, as single-track points out, the wire is weakened and stiffened by twisting.
my favorite bike - R1200GS
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