Sheered off oil filter cap bolt. Help!

[AphoticD]

I was putting the oil filter cap back on my 2008 GS500E and one of the cap bolts sheered off as i gently tightened it up (there are 3 bolts, which  appear to be moulded onto the main block).

I spent hours trying to hold the little bolt in place while the JB Weld epoxy got tacky enough to hold it horizontal under its own weight in an attempt to get the sheered off bolt firmly re-seated.

All looked good after letting it set for a week. I tightened it all up last night (not as firmly this time), filled up with fresh oil and started her up for the morning commute. Within seconds it dumped out about half a liter of oil on the garage floor.

I realized that in the past i would just use a little 10mm spanner, but i had the socket wrench on it when it popped off...so  i can only blame myself, but perhaps my sharing this will prevent others from repeating my mistake.

Can anyone shine some light on some solutions? I feel it may be irreparable... its really got me down

[The Buddha]

Those are studs in the case. I have been able to remove them with a vice grip and use a bolt with the same thread.
Cool.
Buddha.

[AphoticD]

Thanks Buddha! This is perfect. I'll make some time on the weekend to drain it out and go at the bolt with the vice grips. There is hope! 🙏

[Bluesmudge]

Did the stud shear or did the aluminum threads strip?

If the threads are stripped you will probably have to use a helicoil and then replace the stud.

Those nuts only call for like 8 foot pounds of torque. Almost nothing. Just enough to compress the rubber gasket.

[AphoticD]

Success!

I spent a few minutes gradually undoing what was left of the stud with the vice grips and found a 10mm hex bolt with a matching thread in a tub of screws -it was a bit long so spaced it with a couple of nuts.

All back together, refilled the oil and cleaned up. The GS is purring again

I just used the little 10mm spanner to gently nip these up. Took it for a run and no leaks so a wonderful outcome for what felt like a major mess up.

Thank you Buddha for pointing me in the right direction.

I owe you a beer! 

[The Buddha]

Yeaayyyy random bolts bin to the rescue. BTW I've done it on so many bikes I've lost count. many of mine and quite a few on ones I worked on.
There's something about the setup that stumps people - especially air cooled old yamaha owners I've noticed. Cos those also had the same type of filter hatch but with a passthrough bypass integrated bolt. Typically, the yamaha issue is they over tighten it and it will round off when you try to get it off. And when they have a suzuki they do these types of mistakes.
Cool.
Buddha.