I completely f'd it

[kryptek49]

I was replacing the crank trigger on my 92 gs and over-torqued the rotor bolt.

The end has snapped off and I really can't think of a way to get it out.

Pics are here: https://imgur.com/gallery/d1ehH

Any ideas?

[mr72]

If you can grip it at all it may come right out. Otherwise make friends with someone who knows what they are doing and they will tack weld something on to it so they can remove it or maybe use an ez-out. But that's really easy to make it a lot worse if you don't really k ow what you are doing. By a lot worse I mean new crankshaft worse.

Oh and get a torque wrench. And don't trust Suzuki bolts, I've broken several at factory torque.

[kryptek49]

I was using a torque wrench when I snapped the bolt, I hadn't tightened the nut on the bottom of it so it never clicked

Got really lucky and used a centre punch and a hammer to hit the edge and twist it out, phew.

[J_Walker]

Got really lucky and used a centre punch and a hammer to hit the edge and twist it out, phew.

glad you figured it out, I've done the same thing on 3 GS's.. these bolts really never get "stuck" from over torquing. because the threading can't bottom out on anything.

[RichDesmond]

Got really lucky and used a centre punch and a hammer to hit the edge and twist it out, phew.

glad you figured it out, I've done the same thing on 3 GS's.. these bolts really never get "stuck" from over torquing. because the threading can't bottom out on anything.

Torque wrenches, in general, cause far more problems than they solve or prevent. They are sometimes useful, and like all tools have their place. Most of the time, that place is untouched in the bottom of the tool box.

[mr72]

Torque wrenches, in general, cause far more problems than they solve or prevent.

I can't see how that makes any sense.

It's entirely possible to under-torque something critical without a torque wrench.

It's far more likely to over-torque something and break it if you don't use a torque wrench.

It's of course possible to misuse a torque wrench and break things, but it's hard to blame the tool.

I know one thing, work on the suspension on a coil spring Jeep much without properly torquing everything and you are in for a world of hurt. And under-torqued (125 ft-lb!) crank end bolts on Miatae are a super high rate cause of misfires that are tremendously difficult to diagnose, very common when you don't bother with a torque wrench when changing the timing belt. I could go on and on.

In this case, though, much like with my GS, my suspicion is a damaged bolt was to blame. Bolt was probably fatigued or corroded and snapped. I snapped several crankcase bolts on my GS at way below the rated torque because those old bolts were ready for the trash can.