Topic: snapped engine bolt

[DAVE H]

Hi when removing the engine crash bars on my f2 the front left hand engine bolt snapped off.the remaining part of the bolt and nut remaining in the engine lug,tried tapping it out but is well solid,would it be ok to apply some heat to remove it,or has anybody any other solutions thanks.
DAVE H

[nickjtc]

Heat is a good start. Also soaking with a good penetrant. Good luck with that!

[spitfire]

Hi Dave,
             The key thing is to remember DO NO DAMAGE, if it was mine I would clean up the area as much as possible, depends were the bolt is trapped/snapped, in the frame or on the engine, you don't want to damage either.
The nut is a captive one, held in place by the crankcase, clean that area as much as you can, then give it a good soaking with WD40, try tapping the broken end of the bolt, gently just to try and jar it loose, not a full on get out of here bash.
If that does not work, try heat and tapping, if that does not work it sounds like you will have to drill it out, very carefully.
Don't rush spend a few days on each attempt, but as I said earlier clean up that area as much as possible.

Cheers

Den

[silver fox]

I had a similar problem on my BM R1150GS, soaked it for days to no avail, used heat, but to no avail, eventually had to drill it going from a pilot hole upto the point where i was at a drill bit just less than the bolt. Soaked it some more and then using a drift, hammered it out. Once out i didnt think it looked so bad as to be such a pain in the arris, Just dont go at it too hard or hot as you will end up snapping the lug!!!!

Good luck

[nippon]

Hello,
don't worry.
As last solution, you can remove the broken bolt by "spark eroding".
For an explanation please take a look at http://www.sparkeroding.co.uk/
I did it it with a broken engine bolt like shown at the pic. I was not able to remove the broken bolt with heat,
so I took the engine to a shop. The guy removed the bold by spark eroding.
Absolutely no damages on the thread, no need for helicoiling.
The bad thing was, i have paid EUR 40.00 because it was a slow and long lasting process.
In my case three hours to erode the bolt.
But much more cheaper than purchasing a case.
I have tested the thread with my torque wrench when I have replaced my bearings,...I'm absolutely satisfied with the result.

Good luck!

nippon

[DAVE H]

Thanks
for the replies guys,will proceed to the garage, armed with a coffee,and try your suggestions,closely folowed with a couple of beers if it does not come out. The broken part of the bolt is on the engine,will let you know how i get on.
Dave.