OH SH1# Please help!!!

I seem to have a problem. I was wondering if any of you would have a solution to my problem. I began taking my bike apart today, so that I could install new intake boots because the others were shot. When removing the bolts holding the intake boots on, i discovered my problem. One of the boots seemed to be missing a bolt. After i ripped the boot off i noticed that the bolt was indeed still there, just missing the head. I tried to take a vice grips and unscrew the bolt out...it wont budge. Anybody know of a way to fix my problem. My friend thinks that the best solution is to use a helio coil (not sure how to spell it). But i would i prefer this to be my last resort.

Post edited by: jordan, at: 2007/07/11 14:53

try soaking it down with some P B Blaster, let it sit over night, also take a small hammer and tap on the bolt not real hard, but the shock can free things up, and last, try some heat , the last thing would be to drill it and install a heli coil

Spray it down with zep45 tap end with hammer and try turning it out.if that doesnt work heat the area around bolt and repeat process;) run a tap through all the bolt holes and put anti-seize on bolts before installing

Might consider heating the area surrounding the broken bolt with a propane torch. Then, while still hot, whack it a couple time (like driving a nail, but not too hard), then try again with the vice-grips.

Could also apply PBBlaster and allow it to work for a few hours or longer in hopes it might eventually penetrate into and loosen the threads.

If unsuccessful with the above, please report back for more tips before attempting to drill or grind it out yourself. As this is not an uncommon problem, might find some good helpful info by doing a search on this site in the "search forum" box.

As I recall, some have used a Dremel with tiny round diamond grinder head to very slowly and carefully remove the stud without damaging the female threads inside the head. And still need to clean up the threads by chasing them with a tap.

When in doubt, trailer it to a machine shop and get a professional removal job.

Agree that heli-coil should be last resort.

Good Luck!

Cut a slot on the end of the broken off bolt with a Dremel and small cut off wheel. Then, use a hand impact driver and flat screwdriver bit. This will break the galled bolt loose. Once it starts to turn, you can use a regular flat blade screwdriver to remove the bolt or your vise grips. You can try some heat in the area and PB Blaster (you can buy this stuff at Walmart) but I doubt it is needed. These bolts get warm from the operation of the bike and eventually crystalize and get brittle and it isn't unusual they break. If you have some tools, you could also use a stud puller. These things grip engine studs and will work on a bolt just fine if the head is broken off. If you break the bolt off flush, you can drill it out. I would then use a 6mm insert (I use Recoil inserts)... instructions for using the inserts should be included with the insert kit as well as the necessary tap and install tool.

PLUMMEN wrote:

Spray it down with zep45 tap end with hammer and try turning it out.if that doesnt work heat the area around bolt and repeat process;) run a tap through all the bolt holes and put anti-seize on bolts before installing

Concur.
Take your time.
I had stuck bolt that took a week of daily worrying.
It's a hell of a lot easier to spend a few minutes a day for a week or two than to have to pull your head, get it mounted on the drill press or mill, and cut the thing out.

-Duck

Thank You so much for all your help! Once again KZRider has saved me. I just heated up the area, then tapped on the end of it, and with some effort, and a vice-grips it came right out. Thanks for coming through for me once again!!!:laugh: :woohoo: :silly:

i am in the middle of doing this as well. i have tried everything but it wont come out. i finally just gave up and im going to try to do a make-shift repair until winter when i can tear the head down for work. stupid phillips head snapped off and i had a nub to grab on. after repeated attempts of heating,penetrating oil, etc that didnt work. finally i ground it flush and drilled a hole through it with a left handed drill bit, still no luck. i have a $50 set of craftsman easy-outs and i snapped the tip off my smallest one. i got all the other screws out fine and i replaced the crappy original screws with hardened allen head screws. as far as for the bad hole, i am going to run a smaller tap in the bolt and use a smaller allen bolt and maybe a small bead of hi-temp gasket sealant around the outter ring of the inlet. when winters here im going to pull the head, chuck it up in a milling machine. then it'll be a good time to port and polish the head as well.

Invest in some stainless allen head bolts. Use anti sieze also. You can get sets off ebay pretty cheap. I'm glad I changed almost every bolt on my bike over.

if its sticking out of the head, use an easy out bolt, if its in the head you'll have to remove it and drill it out on a drill press.

i absolutely HATE broken bolts. i hate those sinister flathead and phillips screws. in a perfect world everything would be allen bolts. i do mechanic work for a living; just on industrial machinery. i tinker with small motors as a hobby. snapped bolts can quickly ruin your day. since that one screw snapped off its set me back on what SHOULD have taken 15 minutes to do has now been 4 hours of work...6 hours of pondering. the snapped bolt acts like its welded in. ive never had such a hard time. those bolts are so soft i couldnt get any positive grip on the stud. they do drill easy but still no luck. i have a hole approximately 9/64" in diameter but the hole is kinda crooked. im going to run a tap approx. that size and put a temp bolt in for now. any of you who are experienced with the KZ's see this as a problem for leaks? like i said this is temporary until maybe november when its too cold to ride then im fixing it properly but i really want to ride right now. im going to use a hi-temp gasket sealant when i seat the boot on the head.