broken oil filter cover bolts

[fikvdv]

Hey everyone

I drive a Suzuki GS500 F from 2005. After changing the oil today, one of the bolts from the oil filter cover broke off...
I hope someone can tell me if you can replace such a bolt and how you could get the old one out?

A final solution seems to me to drill out the old bolt and tape new thread.

Thanks in advance!

Cheers
Fik Vdv

[Sporty]

Hey everyone

I drive a Suzuki GS500 F from 2005. After changing the oil today, one of the bolts from the oil filter cover broke off...
I hope someone can tell me if you can replace such a bolt and how you could get the old one out?

A final solution seems to me to drill out the old bolt and tape new thread.

Thanks in advance!

Cheers
Fik Vdv

The stud/bolt can be purchased from a Suzuki dealer.  Or if no dealer near you,  a stud can be made from a bolt that has a long enough portion of threads, or from threaded rod (AKA all thread)



Before removing the broken stud, cover up the openings into the engine.

If the stud is a bit loose in the case, you may be able to get it to unscrew by tapping it with a small punch or chisel and small hammer. (So you are tapping in the direction to spin it out)

A very good way to remove a broken bolt is by welding a nut onto it with a wire feed welder (MIG welder)
With Smaller bolts, I'll often weld a washer to the broken bolt, then weld nut to the washer, let it cool off and then unscrew the bolt. A battery impact wrench is good for the removal of the welded bolt. I have removed 100's broken bolts this way.

You can of course drill it and use a screw extractor. It is helpful to grind the broken bolt smooth before drilling.  Grind, make a center punch mark in the middle and carefully drill, starting with a small bit around .125"  (3mm).  Measure the depth of the hole and then Mark the drill bit so you don't drill too deep.

Enlarge the hole for the screw extractor, but don't make it to big. Try not to drill into the case!

Soak with penetrating oil before you try to remove it...

[max]

How much is left of the stud and which one broke (the bottom centre stud obviously has much more free space around it than the top two)? A picture would be helpful.

If there's enough of it left you could try 'double nutting' it first before getting the welder out - you tighten two nuts against eachother then use the bottom one to try to undo the stud.

Or they make stud extractor tools, but again this relies on there being enough stud sticking out for the extractor to clamp around.

Like Sporty said though, drown it in penetrating fluid before anything, but be sure to clean it off before welding.

[herennow]

If you end up drilling it out find yourself a set of left hand drill bits as this loosens the broken off stud rather than tightening it while you drill. Normally comes out while drilling.

For example

10Pcs Screw Extractor Drill Out Left Hand Drill Bit Remover Broken Bolt Cobalt Hand Tools from Tools on banggood.com
https://banggood.app.link/bldAqDmhkbb

[fikvdv]

Thank you all so much for the quick responses! Especially Sporty for the detailed explanation.
I'll try what you suggest and hopefully the thread will come out easily, so drilling won't be necessary.

The upper right one broke and there is about 2 cm thread left so enough to grip it somehow. The double nutting is also a great idea I think.

Thanks again !