Tip For Removing Broken Drill Bits Or Easy Outs

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04 Mar 2016 11:58 #713806 by kzharpe
Long story short, I broke off one of the carb holder bolts on my 77 kz650. I was a machinist for several years so I thought this would be an easy enough fix......it wasnt. I tried multiple easy outs, but like most people with this issue on the forum...it failed horribly. My next step was just to drill the darn thing out and retap the hole. Im fairly confident in my ability to drill a straight hole so I went for it. Needless to say the smaller drill bit I was using to drill a pilot hole broke. At this point I was ready to take off the head and take it to the machine shop. However before that I wanted to try and drill that bit out using a solid carbide bit. Wouldnt you know it, my budy has my carbide bits (he lives 200 miles away). I head for lowes looking for anything that is carbide. I ended up coming home with a rotozip bit that was carbide. I threw it in the drill and fired away. As soon as I got started I heard a snap. The snap was the smaller bit shattering into pieces. A little wd40, a few blasts from the air hose, and a couple more passes with the rotozip bit and I was home free. Pulled out my titanium bits and an m6 tap now we are good to go. Just wanted to share this because it may save someone a trip to the machine shop in the future. Ill post a link to the bit that I used as well. Oh and by the way your going to want extremely high rpm's so I would either use an actul rotozip if you have it or use an adapter for a dremel

www.lowes.com/pd_123166-353-XB-TC1___?pr...&Ntt=rotozip+bits#3d

1977 KZ650
The following user(s) said Thank You: Mcdroid, pete greek1

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04 Mar 2016 13:43 #713824 by car5car
Thanks! I didn't know about carbide bits

96 Yamaha Royal Star
82 Yamaha Virago 920

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04 Mar 2016 13:49 #713825 by kzharpe
They work wonders but solid carbide bits are between $40 and $60 a piece, that's why I'm glad this rotozip bit worked. Definitely going to have my buddy ship mine back asap

1977 KZ650

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04 Mar 2016 14:11 #713829 by 650ed
Thanks for the tip, but it's MUCH easier to use Kroil to break the bond between the screws and engine than it is to deal with broken fasteners. The carb holder screws on mine had not been touched since the bike was new, and after about 30 years did not want to budge. I soaked them for 3 days with Kroil and used a JIS screwdriver bit, and they came out without a problem. That stuff really works, and I would not work on my bike without it. Ed

Attachment Kroil-2-3-4.jpg not found


1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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04 Mar 2016 14:18 #713831 by kzharpe
Yeah I actually just ordered some per your advice. I used pb blaster but it clearly didn't work. Worst part is that it was the very last one I took off the bike. All the others came off no problem

1977 KZ650

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  • bluej58
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06 Mar 2016 05:46 - 06 Mar 2016 05:53 #714078 by bluej58
Recently I had to remove a snapped screw that held the tank badge on , first I used oil and a tiny bit to center drill a hole , I have been down that road with easy outs and didn't want to try it again. :whistle:
I was going to try to beat a small flat blade in there to spin it out.
Like you all I have is PB blaster on hand and I know that the instructions tell you to tap the part and respray so I decided to try using my engraving tool to vibrate it first.
When I touched the tip to the busted screw it shattered the screw and I was able to fish all the pieces out with a dental tool B)

That's good to know about carbide Dremal bits ;)

78 KZ1000 A2A
Last edit: 06 Mar 2016 05:53 by bluej58.
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05 Aug 2016 17:11 #737586 by Tune-A-Fish
Replied by Tune-A-Fish on topic Tip For Removing Broken Drill Bits Or Easy Outs
If any of the broke off part is sticking up, weld a nut to it and turn it out.

I didn't come here and I ain't leavin

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05 Aug 2016 20:47 #737606 by missionkz
Replied by missionkz on topic Tip For Removing Broken Drill Bits Or Easy Outs

Tune-A-Fish wrote: If any of the broke off part is sticking up, weld a nut to it and turn it out.

LOL. Not on my gas tank ...

Bruce
1977 KZ1000A1
2016 Triumph T120 Bonneville
Far North East Metro Denver Colorado

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  • SWest
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07 Aug 2016 10:16 #737711 by markitzero
Replied by markitzero on topic Tip For Removing Broken Drill Bits Or Easy Outs
I've used a concrete drill bit to break out broken drill bits in similar scenarios with success.

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  • SWest
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07 Aug 2016 14:25 #737734 by SWest
I've tapped on them to loosen them enough to pull out with a magnet. PITA but it can be done.
Steve

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08 Aug 2016 13:20 #737867 by westmiltonfab
Replied by westmiltonfab on topic Tip For Removing Broken Drill Bits Or Easy Outs
That works really well, but it also works better when after you weld it walk away and let it cool down before you extract it. Heat makes everything swell so let it cool down.

1980 Kz1000 A4 21000 miles
2005 Road King 150,000 miles
1968 CL125 Honda 11,000 Miles

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