Bolt sheered trying to install X-Heads. What now?

[Hates_]

Finally got some time to install the X-heads and the main bolt has managed to shear off. I was paranoid enough about the torque settings so set mine to 7NM instead of 10NM just to get it going and then this happened

Any advice on how to get the sheared part out?

 

[UturnTony]

May be one of the occasions when something like this may succeed. Drill a hole in the broken in bit and use
an Ez Out like this which screws in left handed to turn the bit out. They will usually only be effective in cases like yours
where the broken bit isn't too tight.

http://www.ebay.co.uk/itm/Damaged-B...225945&hash=item21240231a0:g:918AAOSww3tY5Pff

Other fixes are available.

Edit; If you do try this BE VERY CAREFUL YOU DO NOT BREAK THE DRILL OFF IN THE BIT YOU ARE TRYING TO REMOVE.

 

[Karlos]

I agree with Uturn. This is the only time an ez out will work. How far is the bolt in the hole?


Sent from my iPhone using Tapatalk

 

[Hates_]

Thanks. I'll give this a go.

It looks like the bolt is maybe 3-4mm inside the hole. I haven't taken off the whole valve cover to have a look yet. Scared of shearing off the other bolts too.

 

[roamer]

Did the bolt screw in easy or was it tight after 1 turn ? is it possible it cross threaded, the shear torque is lower than the tightening torque on a free thread, the covers do need a bit of aligning,
if its just snapped the broken bit might unscrew by using a magnetic pick up tool or a thin centre punch or similar, from the look of it you may wiggle it out,
If its solid it may be cross threaded and ideally centre punch the middle of the broken bit and drill it out to app 2mm under the bolt size, then slightly more once you know its a straight hit with the drill.
or have it done for you, its do able, not a fan of easy out on tight threads, , don't worry about shearing the other bolts the originals are quite robust, the hex one appears to be machined from bar,
Roamer

 

[OldCroc]

if its just snapped the broken bit might unscrew by using a magnetic pick up tool or a thin centre punch or similar,

+1 - you could also try and turn it gently with the sharp end of a dart! Worked for me but be patient! Be careful mot to damage/burr and visible threads in the hole!

 

[Hates_]

I'm right in thinking I need to pull the spark plug out to get the cover off?

 

[Andi_archer]

I'm sure I have seen a similar request maybe on advrider with a solution that involved removing the cover so the head of the snapped bolt could be grasped to remove it.

 

[Devil]

Any chance you can get a stud extractor on the remaining part of the stud, or is it sheared level .?

 

[Hates_]

Sadly it looks like it's sheared about 3-4mm deep inside.

 

[roamer]

No need for the plug out, there will,be a bit of oil residue, just take the cable guide off, disconnect the coil and pull it out,

 

[Deleted account 190920002]

OP I used to use a transfer punch ( they come in different dia) to get an exact centre mark on broken stud then use a centre punch to get a good centre pop to drill into then use an extractor. Hope this is some use and you make good

 

[snaponphil]

Extractors

Ouch.. unlucky..
My specialist area. Although it looks like it's broken off below the surface. The ones pictured (can't remember the part number) have a guide to centralise the drill.
Don't use cheap extractors as you only get a few attempts at this then your into recoil (helicoil) territory..
Would also suggest thread restorers rather than a tap to clean threads once stud removed.

Good luck, shame your not closer..

 

[Andi_archer]

You might find the bolt thread is actually lose so something sharp like a centre punch may rotate it out with some persuasion.

 

[Hates_]

You might find the bolt thread is actually lose so something sharp like a centre punch may rotate it out with some persuasion.

Yeah that's what I'm hoping. Will try and ease it out before resorting to drilling it. Fingers crossed.

 

[MKP]

Hates, I'm East of London and have a kit like the one in the picture if you need to borrow one. Send me a PM if you need help and I'll let you know where I am.

 

[darkhorse]

I had the same problem with mine. Drill a small hole in the end of the bolt, only a couple of mm deep, tap in a hex key which will grip on the bolt, and wind it out.

 

[Neil W]

Have a look at this months Classic Motorcycle Mechanics Magazine there is a full article covering exactly this scenario and how to do it properly and what tools NOT to use

 

[2 wheel humvee]

Similar issue here, I took the guards off to clean behind them (rookie mistake I know.....) and the cover leaked oil during a ride on Thursday I nipped it up at the side of the road but didn't like the feel of the bolt so investigated this morning and it snapped flush with the casting similar to the pics above, I managed to centre punch the snapped bolt and twist it out with a combination of centre punch and electrical screw driver until there were 3 or 4 threads proud so I could grip it, I suspect the replacement bolts are made of cheese

 

[Hates_]

Managed to get it out with a center punch and some patience. Thanks everyone for their advice and help. Does anyone know what the proper torque settings for the valve cover are?