im not a happy camper

well i got my hands on a gpz motor to put into my 83 KZ750 L3
i was going around it to clean it up and get it ready to paint and found a broken bolt in one of the intake inlets so i started to try and get it out first by cutting a slot in it as it was still sticking above the hole but that didnt work so i filed the rest of the bolt flush with the hole all is good at this point then i start drilling the bolt still doing good i was about a 1/8in into the bolt then a budy showed up a was going help me out hahaha well what he helped me do is he put a torx bit into a screwdriver handle i did not have my easyouts on hand and he thought hey this the same so he tapped it into the nice little hole that i had drilled into the bolt then broke the tip off and now i cant drill it out any more
any ideas would be great or am i screwed

If you have access to a welder to can weld a nut onto the broken stud and try to extract it that way.
The torx bit is not hardened so it is not surprising that it broke.

i new the torx dit would break but he didnt and by the time i realized what he was doing it was to late and no i dont have a welder i can not aford one nor do i have the skill to use one i have used cobolt bits and oil no dice lol

If the torx is not hardened is there any way to get the broken bit out, and start over again, maybe a dental pick or something could get it. Maybe a small drill bit if you don't break it it might work. If you run out of methods you might have to pull the head and send it to a machine shop which would be a pain in the neck

i think that the bit is hardened cause i cant get any drill bits to bite into it and i did try the dental pick before i tryed to drill it i was thinking about useing a carbide bit

I was in the same boat accept it was an broken easy out. the only thing i did was burn up about seven different drill bits, used super small ones to drill around it and create slack so i could peel it out with a triangular chisel/knife type thing(any thing would work here)

I finally drilled it out and helicoiled it.(it was an exhaust stud)

School Teacher wrote:

I was in the same boat accept it was an broken easy out. the only thing i did was burn up about seven different drill bits, used super small ones to drill around it and create slack so i could peel it out with a triangular chisel/knife type thing(any thing would work here)

I finally drilled it out and helicoiled it.(it was an exhaust stud)

This is a similar strategy to what I did on an intake bolt. I drilled a small hole next to the broken easy out and made a tiny hook to yank out the broken piece.

Krazinite, be very very careful. If you can't get a welder to extract it (which is probably the cleanest method and you may not need to helicoil/retap), be super patient with it. Plan on taking a long time. If you rush it, it can get real ugly real fast. Don't drill deeper than you have to. There are usually enough good threads below the broken bolt to give you something to screw into with a longer bolt when you are done.

loudhvx yup i hear ya im trying to avoid any damage to the threads
which i have dun so far i have work about 5 hours on it so far i will try carbide bit next and if i can get them to bite i think that will work and when it comes time to use easyout i will heat up the area around the broken bolt cross my fingers and hold my tunge in the right place and see what happens

If you get something hard like a drill oe easyout broken off in there, then you have to remove the head and have it EDMed out.

Jay

its a torx crewdriver bit

Try this.

Take a small chisle and grind it so it's very narrow.

Use a simple butane torch to put some heat around the broken bolt. Hit it with penetrating oil, let it soak in for a while. Heat it again, more oil....

Then use the chisle and small hammer & try to get a bite on what's left of the bolt and unscrew it.

You might even let the pentrating oil work overnight...

Buddies always have the "best ideas"...don't they

I've been lucky on many occasions by using a "automatic" see "spring loaded" center punch in breaking "hardened" bits and removing piecemeal. (carbide drill bits/taps). High carbide steel while enourmously hard,is brittle. the concentrated impact/relatively small force has saved my bacon many times. Luck g