Hi,i've got an '04 250 pro.anyone out there broken a pedal off the frame.....and if so how did you repair it?

Hmm, AFAIK it's a forged item and will not weld well. Replacement is your best option. This happened to a friends 315 Mont.

I'm guessing you mean that you've sheared the bolt inside the frame & not the actual pedal? I did one like this & the way we got round it was to weld a bolt onto what was left, I was lucky as there was just enough left sticking out of the frame. It took 10 goes or so to actually get a good enough weld to stick to just the bolt & not the frame but it do work. Al the Spanner told he done one by guessing were the hole should be & drill through from the outside, this is now a good way as you can get a good point of reference from a newer frame with the bolt on the outside.

I'm guessing you mean that you've sheared the bolt inside the frame & not the actual pedal? I did one like this & the way we got round it was to weld a bolt onto what was left, I was lucky as there was just enough left sticking out of the frame. It took 10 goes or so to actually get a good enough weld to stick to just the bolt & not the frame but it do work. Al the Spanner told he done one by guessing were the hole should be & drill through from the outside, this is now a good way as you can get a good point of reference from a newer frame with the bolt on the outside.

Cheers Perce,thats the line of thought we had,just gonna strip the back end off today,then i can have a good look at the beasty.

Hi postmanpat,

Perce and Al have it sussed. We had one here where the bolt sheared off flush. The only way out was to drill from the outside of the frame, using a really good guess for the hole centre, then pick out the broken piece. The bolt is sst making it even more difficult. A lad here suggested to prevent this from happening (always easier in hindsight), to first remove the bolt then grind a point on a 40mm long 8mm bolt and tighten it through the frame so that the point impinges into the outer side of the frame to give you an accurate mark to drill the frame for using an 06 type bolt arrangement, if you know what I mean. If you wanted to re-use the 04 bolt then best to cut a screwdriver slot on the end of the bolt to assist in future removal from the inside of the frame.

Bye, PeterB.

Got the repair done,drilled the frame and tapped the hole out m8,then drilled the bush out m8 and welded a bolt in.......job done.Thanks for your replies.Chris