Broken Head Bolt

[5azzmonkey]

I just started an overhaul on my 82 GS1100E which has been sitting garaged ~10 years now. When I parked it the small head bolt near the timing chain and exhaust was dripping oil. I loosened it a couple turns and then went to tighten it and it snapped clean off. Yes, I was using a torque wrench set to ~95 inch pounds.

The bolt in question is #10 on the attached diagram,

What's the best way to remove this? I'm thinking of bringing it to a machine shop 'm afraid if a try and drill a hole in it for an easy out it will slip and drill into the head and ruin it.

There also seam to be a good amount of carbon build up on the valves and cylinders. Should I just leave it, clean it off (how?) or have the head rebuilt too.

[JEEPRUSTY]

I just started an overhaul on my 82 GS1100E which has been sitting garaged ~10 years now. When I parked it the small head bolt near the timing chain and exhaust was dripping oil. I loosened it a couple turns and then went to tighten it and it snapped clean off. Yes, I was using a torque wrench set to ~95 inch pounds.

The bolt in question is #10 on the attached diagram,

What's the best way to remove this? I'm thinking of bringing it to a machine shop 'm afraid if a try and drill a hole in it for an easy out it will slip and drill into the head and ruin it.

There also seam to be a good amount of carbon build up on the valves and cylinders. Should I just leave it, clean it off (how?) or have the head rebuilt too.

When you pull the head and cylindes you wil have access to this nub of a bolt. You or anyone cannot heal a leaking gasket by tightening a bolt. Once a gasket has cinched up it has reached its limit.
Any thing beyond a cinch is asking for trouble in the form of a snapped bolt. Be happy it was not a worse bolt in a less happy place.

[5azzmonkey]

Actual pic of head

Head with broken bolt

[JEEPRUSTY]

Head with broken bolt

Hell man you got the thing exposed go to a machine shop.
****ing around with a drill will only make things bad.

[5azzmonkey]

When the bolt snapped it wasn't even tight against the head. I figured it was worth the chance to try , worst case is it still leaked. Until the bolt broke!

[JEEPRUSTY]

When the bolt snapped it wasn't even tight against the head. I figured it was worth the chance to try , worst case is it still leaked. Until the bolt broke!

leaks are going to continue in such a place because the clampig force on the joint has no signifigance. Once oil has passed the idea that you can tighten a bolt to stop a leak is past.

[5azzmonkey]

yeah that is what I figured. Didn't take long to pull it everything came apart pretty easy except the end cap covers, 3 of them are still on the valve cover soaking in sea foam. Why did they have to use Philips head on those!

Thanks for the quick response

[JEEPRUSTY]

yeah that is what I figured. Didn't take long to pull it everything came apart pretty easy except the end cap covers, 3 of them are still on the valve cover soaking in sea foam. Why did they have to use Philips head on those!

Thanks for the quick response

You will get a fab site wlcome soon form some zen buddhist guy who cannt play a guitar so he plays bass. Which we all know is a fish.

Anyway lots of resources and lots of manuals etc coming your way in a greeting soon.

Do not lanet the snapped bolt. It caracked under pressure. Now that has been relieved it should spin out easily whi a left hand drill bit.

[5azzmonkey]

Thank You ... This site is great I've been browsing it for the last couple of weeks, lot's of great info .........

[rapidray]

Where are you located? Ray.

[sedelen]

My '82 GS1100E had a minor leak at the same bolt. Like you I tightened it a little, mine didn't snap though, and the leak stopped. After reading
about your situation, I feel pretty fortunate.

With the head off it shouldn't be too difficult for a machine shop to remove that bolt.

[5azzmonkey]

Ray,
I'm in Connecticut. I have been riding lately with friends in Nebraska on a borrowed bike.

All,

I talked to my mechanic last night and I am dropping the head off at his house tonight, he said he should be able to get the bolt out for me. We are also going to hone the jug so I can replace the rings. I figure I minds as well while I'm in there.

[rapidray]

Order 2 new orings for the front 2, center head nuts while you are at it. Ray.

[5azzmonkey]

Order 2 new orings for the front 2, center head nuts while you are at it. Ray.

Does anybody know what size they are and what the material should be? I expect it will be much cheaper at my hardware store and/or mcmaster.

[bonanzadave]

They are about 4 bucks a piece at Slowzuki....

http://www.thegsresources.com/_forum/showthread.php?t=175380&highlight=oring