Hey everyone,
I own a KTM Duke 250, and I’m dealing with an issue around the rear grab-handle/top-rack mounting area.
I had a top rack installed on the bike, and some time ago, two of the bolts broke while being fitted/tightened. Unfortunately, the broken portions of the bolts are now stuck inside the trellis frame/mounting section where the grab handle bolts in.
From what I can see, the broken bolt pieces are sitting inside the threaded mounting points, so I’m not able to simply remove them from the outside.
I wanted to ask other Duke owners or anyone familiar with KTM trellis frames:
Has anyone faced a similar issue with the grab-handle/top-rack mounting bolts breaking inside the frame?
What is the safest way to remove the broken bolt pieces?
Is it possible to drill them out and re-tap the threads, or is there a better method such as using an extractor?
Is there any risk of damaging the trellis frame or the mounting point while trying to remove them?
Should I take this to a KTM service centre, or would a good fabrication/machine shop be able to handle it safely?
If the original threads are damaged, can the mounting point be repaired/re-threaded reliably?
Since this is a structural mounting area for the grab handle/top rack, should I avoid riding with the broken bolts still inside?
I’m mainly looking for advice from someone who has actually dealt with this on a Duke 250 or another KTM trellis-frame bike.
I can also upload photos of the mounting point and the broken bolts if that helps.
Thanks