Removing snapped bolt from engine side-case--vice grips or bolt extractor?

[paalak]

A few  months ago I snapped one of the bolts on my engine side-case cover due to over-torquing it. This is the one on the left side, where the sprocket cover is. I just ordered a replacement bolt and a new side-case gasket from Bikebandit and am planning to remove the cover, extract the snapped bolt, and replace it in order to fix an oil leak that's been dripping oil all over my left boot while riding. Because opening it involves draining the oil I want to make sure ahead of time that I have the right tools so I can fix it the first time and not have to remove the cover and drain the oil twice. So I'm hoping someone who has removed the left-side cover before can give me a sense of whether the bolt broke off flush with the engine or a little above the surface of the engine case. That will determine whether I can get the bolt out with vice grips or I'll need to drill and use a bolt extractor. (If it's the latter case I'll probably take it to a shop to get it done by a pro.)

I stuck a screwdriver into the hole to see how far in it's broken, and it's 21mm. That's right about where the case cover meets the other half of the case:



So the bolt is broken right where that seam is that runs around the case, the line where the cover detaches when you remove it. I'm guessing that's probably flush with the engine, but wanted to make sure. If it would be possible to remove with vice grips I'll take the cover off and do it myself. Otherwise I'll just save myself the trouble and take it to a shop. I'd appreciate it if someone who has had the cover off could let me know if there will be any bolt sticking out when I remove the cover.

[cbrfxr67]

I'd take off the cover, use die grinder and cut a / across it and try to back it out with a flat head.  If you can't do that, a left handed drill bit might catch before you'd have to use an easy out.  I've used left handed bits a few times and the fastener let go before I even had to tap in the easy out.  You might even be able to use the left handed drill bit and get it out without taking the cover off if you're lucky.  I could answer your question on the 21mm mark if I were at the 'shop' today.  I can check tomorrow if noone else answers before then.

[Big Rich]

It probably is gonna be close to the engine. But unless the threads were bottomed out when it snapped, it shouldn't be too tight. Does it have loctite on the threads?

If you carefully use a small flat head screwdriver and a hammer, you should be able to tap on a broken edge and spin it loose.

[mister]

Buy a pair of vise grips just in case. If you don't use them you now have a tool that is useful and which you should have had in your arsenal anyway 

As for whether you need an easy out, notched head or shop or whatnot, you won't know Until you take off the cover. So do that first then post pics.

Michael

[paalak]

I removed the cover today and found the bolt had broken off just about 2mm above the surface, so I was just able to get it out with vice grips 

That turned out to be the easy part. Getting the old gasket off took forever, it was really stuck on there. Ended up having to use a utility knife to scrape it off. Put on the new gasket, re-installed the cover with a full set of bolts, then took it for a test ride. No more leaking 

My one worry is that maybe a few small bits from the old gasket got left behind in the engine case after I closed it off. It was impossible to keep a few bits from falling in as I removed the gasket, but just before putting the cover back on I cleaned the whole area out--wiped it down with a clean rag, then used a can of compressed air to get the last few bits out. It looked spic and span, but I couldn't be completely sure that some little bit wasn't left somewhere out of sight. Should I run some sea foam through the engine to be sure? Anything else I should do to be on the safe side? Didn't notice any problems at all while riding, but I've heard little particles getting into the engine can cause long-term damage.

[Big Rich]

A vacuum cleaner would have been my first choice.

Forget the seafoam- it wont do anything for gasket bits. Run the bike for 5 minutes then change your oil and filter. For extra peace of mind, you can pull the oil pan off and check the screen under the oil pump. Of course, there's another gasket for the oil pan......

[paalak]

Thanks for the tip. I'm pretty sure I got everything out. I went over it a bunch of times with different rags, than gave it a few passes with the compressed air. By the end, no new bits were coming out, and I couldn't see any in there. I guess I'm just being a bit paranoid, in case there was some little blind spot where I couldn't see. But even then, the air probably would have gotten there. Wish I'd thought of a vacuum cleaner, but I think the air can did the job. I'll try checking the oil pan if I start noticing any problems with the engine. So far so good though.

[alyoopz]

Gasket remover helps...  methylene chloride.  You'll know immediately if you get a drop on your hand or arm  :  )

Al