Snapped camshaft journal bolt :(

[cmat1120]

Hello, so I may have accidentally over-torqued a camshaft journal bolt by a pound or two and the bolt snapped with about two threads left on the side that has the bolt-head and the rest of it inside the engine head. Anyone have any advice? There is definitely nothing to grab on to(it's very recessed, plus there's thread-lock on it now) so would it maybe be possibly to just screw it in and hopefully those two threads plus the other screw is enough? This sounds pretty stupid even to me, but it doesn't seem like a spot that requires a lot of holding force and I don't know what else to do. This is not a super nice bike that I care a whole lot about(although it is my only one), so I'm ok with accepting some risk, but not too much and safety would probably be an issue. If anyone can give me some advice I'd appreciate it a lot.

Thank you!

[adidasguy]

There IS a lot of pressure there. The caps hold down the cams and as the cams press down the valves there is lots and lots of upward force.

Pictures?

Lots of advice will come but a picture of the carnage will help get you the right advice.

[cmat1120]

Heres some pictures. I don't have a camera so I used my webcam so they aren't the highest quality. However I did get the head out of the bike so I guess I could possibly extract it now. Although I've never extracted a screw and don't know how.

[adidasguy]

There have been numerous threads on broken bolts.
Most would say
1. Be careful
2. Don't over tighten next time
3. Get a screw extractor kit - probably from Harbor Freight or Sears

The bolt is harder than the head. You'd drill into the bolt then use the extractor. Some say to try a reverse thread drill.

Others can chime in. It will have to come out.

Threadlock is not normally used there. The heat would soften/melt it so it wouldn't be of much good anyway.

[cmat1120]

Ya one of the problems of being a teenager is careful is not the easiest thing for me  , I misread the torque settings(used the nm number instead of lbs). So now I'll never do that again. I think I'm going to have it taken over to our mechanic and let him take a look first since my dad had to go by there anyways and if he can't help or it will cost a lot I'll go buy an extractor kit and try and learn how to use it. As far as thread-lock I didn't quite understand the use for it there either, but I was following a tutorial on beergarage and it said to use it. I will not use it when I hopefully put this back together. Would anyone happen to know the best(cheapest) place to buy a replacement for that bolt? In the hopes that it can be safely extracted. Also while on that topic would anyone know where to get the self locking nuts that go on the frame bolts and the bolts that go through the motor? The Ace nearby only had some nylon insert nuts which I wold think would work, but maybe the original style is better?

Thank you very much!

[adidasguy]

A mechanic could take that out real fast. Probably 10 minutes at most. Maybe $20.
Then you need a new bolt of the same type and strength. I have them if you can't locate one.
Remember the little steel sleeves that go in there where each bolt goes to align things. If you lost any, I have extras.

[cmat1120]

So I think i can get that bolt for the journal for a couple bucks plus shipping so I'll probably do that since I'll know its the right material/strength, but then the locking nuts for the frame are $2 each plus shipping and I need like 12 of them. Is there a cheaper place to get these? They don't seem like anything special. Would the nylon insert nuts handle the job fine? I'd rather have the original style, but they seem kinda silly expensive for just some nuts and I'm on a very low budget.

Thanks

[cmat1120]

A mechanic could take that out real fast. Probably 10 minutes at most. Maybe $20.
Then you need a new bolt of the same type and strength. I have them if you can't locate one.
Remember the little steel sleeves that go in there where each bolt goes to align things. If you lost any, I have extras.

Hey adidasguy, do you think i could buy one of those bolts and one of those little sleeve things? I thought I had all the sleeves, but apparently I lost one. I'll PM you as well.

[adidasguy]

A couple bolts and spacers/guides are going out to you.
No charge. People send their extra stiff to us here in West Seattle then we give it out when someone needs it.
Just pay the favor forward when someone else needs something from you.

[yamahonkawazuki]

A couple bolts and spacers/guides are going out to you.
No charge. People send their extra stiff to us here in West Seattle then we give it out when someone needs it.
Just pay the favor forward when someone else needs something from you.

[knowles]

A couple bolts and spacers/guides are going out to you.
No charge. People send their extra stiff to us here in West Seattle then we give it out when someone needs it.
Just pay the favor forward when someone else needs something from you.

Yes we do. 

[adidasguy]

Yep - we are sort of a clearing house and warehouse for parts.
Even the techs at my dealership asked if they can call me when someone comes in with a GS500 and they have questions. Of course! And they asked if they needed hard to find GS500 parts? YES - Glad to help! I support my local dealer because I get loads of FREE advice and help. Only fair to return the favor. They are not aware of all the parts compatibility over the years or what parts SHOULD always be new and never used.
When I need 1, I order 4. Just to have in stock when someone comes over. I'm better stocked on GS500 parts than the dealer.

HOWEVER - the air box drain hose? Ordered a new one for Husky (that bike will get all new or NOS parts whenever possible), and it came in with the wrong end.NOT the peeeenis thingy so we have gone round and round over that. They got a Suzuki specialist to straighten that out. Right part number - wrong part. That's what my dealer does. gets thing right for a common $15 part. I doubt BikeBandit or RonAyres would do that.

Oh, and yes, I do clean and sort parts because I know lots of things like a bolt - why spend $1 and $9 postage? That;s why people send me their extra parts and we send them out as people need them. And the common bolts are the really expensive things from an on-line dealer. Usually free or just postage from here.

(OK - sometimes we do charge a little for postage and parts, but just enough to cover expenses and keep the bike cave running. Always cheaper than the on-line places.)

[adidasguy]

A couple bolts and spacers/guides are going out to you.
No charge. People send their extra stiff to us here in West Seattle then we give it out when someone needs it.
Just pay the favor forward when someone else needs something from you.

Yes we do. 

Gorilla is getting a headlight. Then someone WILL get his road-rashed one  when they need on just to pass inspection and can't afford a good one. We are big on re-cycling parts and not throwing things away. We may not want a crappy speedo but someone may need it in order to get their bike licensed where it don't matter what it looks like as long as it is there.

[burning1]

there's thread-lock on it now

Woop-woop-woop DANGER! DANGER! Warning!

Never ever ever use thread lock on a camshaft cap-bolt. In fact, never use it unless it's specifically called out by your manual. Thread lock completely throws off the torque reading on your fasteners, and definitely causes these kinds of problems.

[sledge]

Never ever ever use thread lock on a camshaft cap-bolt. In fact, never use it unless it's specifically called out by your manual.

Wise words, and ones I second