broke engine bolt off in front sprocket cover

[santeria13]

Hi all,

Recently wrecked my gs and have quite a big crack in the stator cover, leaking quite a lot of oil. Well at least initially, but i suspect it is now nearly drained of oil altogether. So, basically, I am an idiot. Forgot to change my wrench over to loosen and ended up over tightening and breaking one of the bolts as I was removing the sprocket cover. The actual stator cover is still on, for now.

Here is a pic:


I broke another bolt as well as it seems it was over tightened already or the previous user had put a stupid amount of loctite on the bolt however managed to get that one out by drilling out a line in the middle with a dremel and then using a flat head to wriggle it out.

As you can see however, this one is not accessible with a dremel or even a plier.

I was thinking to take one of my 7mm sockets and stick some jb weld where the nut should go and then weld it to the broken screw inside as there is a bit of clearance. My plan is then to simply rotate left until it wriggles out. My friend reckons this won't work but can't really tell me why.

Anyone else with any ideas or input on what I was thinking? Would be much appreciated.

[Watcher]

You could try the JB-weld/eopxy route, but I can almost gaurantee you that A) the epoxy will probably "run" and affix itself to the sides of the crankcase cover as well as the bolt, B) won't hold against the torque you need, and C) when it breaks off it'll make it even harder to do it the correct way.  Which is with one of these:





You need a screw extractor set.  Basically you drill a pilot hole in the bolt, then insert the extractor with a hammer.  Put a wrench on the end and turn.  Easy peasy lemon squeezy.

[Cerberus]

It's just a sprocket cover bolt I would just leave it. Still have plenty of bolts holding the cover on.

[peteGS]

Not quite... pretty sure the 500 is the same as my 450... the clutch actuator is part of the sprocket cover, so those bolts actually take the pressure of the clutch as well, so I'd highly recommend getting it out.

An extractor is probably the only option being recessed like that, but take great care and caution as extractors are typically quite brittle and can snap easily. As they're typically hardened material they can be extremely hard to remove if they break while extracting.

Edit: Actually forgot one tip... try a left hand drill bit first before the extractor. If you're lucky (has happened a couple of times for me), it will bite enough to unscrew. If it doesn't, you at least have your hole for an extractor.