Allen wrench size for 04 Roadstar XV1700A floor boards?

[WMassRider]

Hi Folks.
Wondering if anyone else has run into this issue.
I am looking to install highway bars onto my 04 Roadstar but need to remove the floor boards to do it. The Allen head bolts seem to require an odd size I don't have. Somewhere a little larger than 6 but smaller than 7. Even the SAE sizes I have don't fit and I don't want to deform them trying to use an undersized Allen wrench.
Did Yamaha use a size that has since become non-standard? It's larger than 6 but smaller than 6.5 or 1/4". Gone through all my metric and SAE but nothing closer than the 6 and it has a lot of play in the bolt heads.

[Shores]

8 mm fits mine. Make sure you clean out all the dirt.

[Lug Nut]

It's either a 6 or an 8 mm. No half size. Best to get pretty decent hex head bits not cheapies. Maybe somebody before you was in there and rounded them off. Would not hurt anything if you got a torch and heated the head of that bolt as much as you could before you tried to undo it. Otherwise you're going to be in for a mess of having to use a Dremel to cut a slot in it or drill it out.

[KFallsRider]

Where the bracket bolts to the frame..? Is an 8

[WMassRider]

A 6 is too small in these, 7 won't fit so an 8 is way out.
I thought perhaps the floorboards were changed out with different bolts but they are the same on the stock passenger pegs.
The bike is in like new condition, no wear or anything on the bolts. It just does not make a lot of sense to me.

Oh yes, it's where the bracket bolts to the frame. Seems to me this size wrench is a bit small for those bolts.
Brake pedal and exhaust are aftermarket so maybe they swapped out the bolts on the floorboards and pegs but it seems unlikely.

Thanks for the input guys.

[Shores]

If they have never been removed, they are extremely tight the first time you remove them. Maybe somebody stripped yours or change them. An 8 mm is perfect for mine on my 2008 and I'm sure all years are all the same.

[WMassRider]

These bolts are pristine so I don't think they have ever been touched. I just measured them with calipers at .245 which comes out to 6.223 mm. I guess it is intended to be a 6 but there is a lot of slop with a good 6mm allen wrench in there. Guess I will just have to try it.
I was wrong about the passenger pegs though. Same type of bolt but 5mm head.

I think maybe I need to find a 6mm impact driver head to break them loose quick and clean rather than trying to use an allen wrench and maybe stripping out the head. I really don't want to end up having to drill them out just to put on highway bars.

Thanks for the input guys.

[MidnightRide]

Pretty trick looking bike. Haven't seen a Roadie done-up that way. Great colors, even the headlamp!

[roadiemort]

Stock bolts that mount the floorboard bracket to the frame are 10mm dia. ,so 8mm allen sounds right.https://www.yamahasportsplaza.com/oe...stand-footrest

[roadiemort]

Non stock, these are M10 also but use 6mm Uncategorized Groups allen.https://www.ebay.ca/itm/393078563419...AAAOSwyKNf70qA

[roadiemort]

The hex is measured diagonally not straight across the parallel sides.

[KFallsRider]

Can you get the bar on without taking them off..?.

[WMassRider]

Can you get the bar on without taking them off..?.

No, the design of the bar requires a plate go behind each floorboard to provide the lower attachment points for the bar. Then I have to drill the center mounting hole up on the frame.
It's a bit annoying but I did not see a lot of options for this bike.

[KFallsRider]

You bought a badly designed bar mount…Yamaha Big Bar is the way to go…or any bar that mounts without going thru all that hassle

[roadiemort]

Probably using an H D bar is why.

[Brad_G]

I fudged up one of the passenger floorboard bolts due to exhaust being in the way. Ended up doing the drill the head off routine. Wasn't a lot of fun. You have a good idea with the impact driver. As Lug Nut said, a little heat will help if you can.

[Mr. Miyagi]

I mounted a Linbar on mine, it needed the hole drilled at the top (use a short bit!). I had to take the floorboards loose and mount the top and the bottom had some short plates that went from the board mounts to the bottom of the Linbar.

[WMassRider]

I mounted a Linbar on mine, it needed the hole drilled at the top (use a short bit!). I had to take the floorboards loose and mount the top and the bottom had some short plates that went from the board mounts to the bottom of the Linbar.

Yep, Linbar is what I have to put on. Not looking forward to drilling through that thick wedge. Just gotta find a 6mm impact allen head. Home Depot was sold out of only that size and everyone else locally only sells sets.
Maybe I will get to it next week.

[davej]

They have loctite painted on them from the factory. They need to be heated to break the loctite.