What to do? broken front brake disc bolt!

[scalveg]

The first time in my life I've broken a bolt trying to LOOSEN it.  Anyway, finally got my parts (new EBC rotor and pads) lined up and a nice free Saturday.  Got the front wheel off with no problem at all.  Check the manual, says that the bolts are in with Loctite 272 (blue).  Okay I have some of that.  Manual also says only replace the bolts with special Suzuki parts.  No problem, I'll be careful not to damage the bolts.

These bolts are hard work!  I could barely move my socket wrench with 6mm hex driver, and I've been working out lately!  I get one of the bolts out a couple turns, and move on to another one.  It comes out a couple of turns, and I move on to a third.  Strange thing is, when I have taken apart Loctite blue hardware before, it's hard at first, but after you break it free, it gets way easier to take out.  These bolts weren't doing that.  Third bolt though, hard to turn at first, but then got way easier.  The problem was there was a loud 'PING' right before it got easier.  Yep I broke the bolt.  Only two threads are visible on the part of the bolt that came out.

So, the situation is that I have the wheel off the bike, and one of the brake rotor bolts is broken off in the hole.  Two bolts appear to be slightly loose, but may just be in the process of also breaking off in their holes.  Two I haven't touched yet.

What should I do?  Is it possible and/or safe to drill it out and put a Helicoil or similar?  How much does Suzuki want for a new wheel?  Will I have to pack the bearings and stuff myself?  Is there any place I could get a used wheel?  I've been off the road for so long it's super-annoying to have this happen!

Thanks very much for any advice!

Chris Owens
Oakland, CA

[ohgood]

Don't know what size that particular bolt is, but I'm a big fan of left-hand drills. The drilling process heats things a little, and we all know that stuck bolts love heat. The left hand drilling also tends to hammer on it a little, and help loosen it. IF you're confident with your 'lectric drill, have at it. If not, I'd pay a fella that is. Decent shops wouldn't charge you more than $20, and you get to keep the wheel instead of scraping it

Besides, machinists like a break from the stress of big expensive crap that has ridiculous tolerances and a chance to think about motorcycles for a few minutes !

Spray it with KROIL prior to pulling a loctite'd bolt next time, several times while sitting overnight.

Oh, and ya, the blue loctite has always had a little pop then the bolt was free for me. Maybe someone pushed the RED loctite button by mistake last time for that one.

Good luck !

[werase643]

try removing the other 4 bolts
if they come out
install the rotor with 4 bolts
ride
if another one breaks.....heat the  remaining bolts with a torch
then remove

5 bolts is good
4 won't kill you