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The Asian Persuasion
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Discussion Starter #1
this bike seems to be bad luck for me.

anyways, i got my case cover off and powercoated. in the process of putting it back on earlier this morning and happen to break a bolt off. it broke way too easily as i was hardly applying any pressure tightening it.

anyways, oily case cover p/c:




and broken bolt:



ideas on what to do?
 

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The Asian Persuasion
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28,564 Posts
Discussion Starter #4
i have no idea. it just broke off like it wasn't even attached!!!

now i have to find another bolt too! :(
 

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That sucks about the bolt. If you can't easyout the remainder its time to drill it out and tap a new set of threads. I'm thinking if it took little force like you said it did to break it, it should be easy to drill out with an easyout. I'm not a fan of the glossy powdercoat. Definitely would look hotter with the colour matching the frame IMHO.
 

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The Asian Persuasion
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28,564 Posts
Discussion Starter #6
yeah it was the only color avail when i got my pegs done so i went with it for everything else.

so much for riding this weekend coming up. i guess i'll have to go see if i can rent a tap-out or whatnot and find me a new bolt...
 

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The ULTIMATE 1 Upper
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2,506 Posts
I just recently had that happen on my left side on one of the bolts on the front sprocket cover. SameRR and I tried for hours and couldn't get that f'er out. A local dealership ended up doing it for free. I didn't bother asking how. Good luck!...O
 

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Easyout. You drill a small hole in the middle of the broken bolt (grind it flat first if you can, then mark with a punch). Then with the easyout either in a socket/ratchet or drill you turn it out lefty-losey. If that doesn't work you already have a pilot hole in the center of the bolt to drill it out completely. Oh yeah, spray the crap out of it with penetrating oil too.
 

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eh-TEE-OH-clez
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easy out should take it out in a second.

Next time, use a torque wrench so you know exactly how much pressure you are applying.
 

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If you pull the cover back off is any of the bolt exposed outside of the block or is it down inside. If there is a little to grab hold of try a pair of vise grips first, next option would be to cut a slot in the bolt to try to use a flathead screwdriver. If all else fails then go for the easyout, they are not so easy. Worst case scenario would be that you have to drill the old bolt out, open up the bolt hole, and then thread in a Heli-coil insert.

Or you could just leave it the way it is, fill up the hole with some RTV sealant, then shove the head of the broken bolt back on and let it dry.:toothy12:
 

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The Asian Persuasion
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Discussion Starter #11
ugh! i just tried for about 10mins knocking the seal loose and no luck. guess i'll try again later on this wk or so. that sealant is on there good when i put it back on!
 

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There probably is still enough of the old bolt exposed to grab with a pair of Vice Grips and twist out. The 03-04 manual doesn't say what the torque values are for those bolts, but identical bolts elswhere on the bike have values of 11 Foot Pounds. Harbor freight sells cheap torque wrenches.
 

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I think all the bolts that size on the bike are the same torque specs.
 

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Per the manual some of the same sized bolts around the alternator and clutch cover areas are anywhere from 9, to 10 to 11 to 14. I broke off a bolt putting my stator cover back on with my torque wrench set to 14 foot pounds. It just barely snapped at 14, so I backed it down to 11 with no ill effect. It's really odd that the manual lists torque values for every single bolt on the bike except for these... unless the torque value is hiding somewhere in an atypical location.
 

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The Asian Persuasion
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Discussion Starter #16
i appreciate all the help guys. i'm hoping to break loose the sealant that i put on and get the bolt out later on tonight when i get off work.
 

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The Asian Persuasion
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28,564 Posts
Discussion Starter #17
i just want to thank all for the help again.

after i relaxed for a few when i got off work, i finally got the sealant loose. with the cover once off again, there was just a little, and i mean very little of the remaining screw poking. it was loose enough though that i got it off with my fingernail till i could get more hold of it with pliers.

hope to find a screw tomorrow at the shop down the road, reseal it and gingerly put the cover back on.

thanks again.

edit - also, what is a easy way to get some of the sealant off before i put another layer on? rubbing alcohol, etc?
 

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a six millimeter fastner ( as is that which you broke ) should be torqued to 6-9 lb/ft , or 72-108 in/lbs , best being 90 in/lbs . don't know where some found the 14 , as that's sure to cause your problem .
 
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