Topic: It's one thing after another (help needed, again!)

[Ketch]

I have a bolt stuck in my cylinder head.
Any suggestions on how to remove it?

[HondaMan]

First you must find a lot of good rags to plug up all those nearby holes. 
Then, get a screw extractor for the bolt size (Ace Hardware carries them), get the one that comes with the drill bit. Drill the hole into it, then remove all the filings. Stuff new rags into the holes, away from the working area if you can, so you can heat up around the bolt with a torch. Then back the screw out with the extractor bit.
 

[Kframe]

Yep that's pretty much the only right way.  (Well, short of EDM, but that's not necessary here.)

If you've got a shop vac, buy a long neck small funnel at NAPA and tape the bell to the hose, and now you have a powerful small suction tip. 



Use that to vac away filings as you drill.  Get the nozzle right up there.

Another trick is to goop grease all over the area to be drilled, to catch the filings and hold them in a big gob.

-K

[Ketch]

got it out with a regular everyday 1/8 inch metal drill bit drilled into it and then used a 3/16inch in reverse and the heat and pb blater and it came right out love it thanks Bucky And honda man.
  NOW anyone got a good place to get the replacement bolt?

[Ketch]

just so you know i used the bunched up rag technique

[Indiana John]

For stuff like this, I like to use my left-handed drill bits. More often than not, they will drill in a ways then grab and back the screw right out. We just did this with a couple of stripped screws on my Gold Wing project.

IJ

[HondaMan]

Most bike shops carry the bolts: go to KawasakiPartsNation.com online, look up the Honda parts fische for your bike, find the bolt in the exploded views and write down the length and size. Nowadays, even Ace Hardware is carryin quite a bit of metric stuff than can work OK (heck, just look at all the metric chrome on MCrider's beautiful build: it's all Ace Wardware stuff!).