Cam Caps Bolts.

[Redman]

Last fall I found 3 broke off and missing.
And have been running it that way, just ignoring it actaully.
But I knew I really didnt want to be going too far away from home like that, and have some catastophic failure like half a cam flying out of the engine or something.

Now I have 7 bolts broke off.
Yes, I did the other 4. Depressing.

Seemed to be drastically over tourqued. When trying to loosen them, at first they just would not budge. If I gradually increased the tourqe, they would twist off. If I tapped or jogged them they would go 'creek' and break loose or they may twist off.

Am thinking of the previous owner . . . and am tempted to violate my morals.



I tried the 'tap along the edge with a center punch' trick with no sucsess. Is kinda hard to get at them with the way they are recessed. And I dont have much of a center punch.

So whats anybody think?
Whats likley to happen if I take to an automotive machine shop?

The valves and cams are good, so would prefere to have this head repaired rather than get a salvage head. But suppose I will do what ever is most cost effective.

Anybody have a 1100 8 valve head available for sale? Any other options? Any other words of wisdom?

[RacingJake]

Call a few machine shops and see what they say about EZ outs

[bikechump]

buy yourself a heat gun, screw extractor set and go at it. trust me that heat does wonders on those aluminum castings. biggest problem is of course access. i would personally pull the motor, drilling strait into the bolts without marring the actually head will be next to impossible otherwise.

good luck

[chef1366]

I would pull the head and bring it to a machine shop. Hopefully you have a metalhead friend. I wouldn't think you have to pull the motor to pull off the head. You'll need a new head gasket.

[mblab]

I've had success with a left hand drill bit sometimes. Seems that as it drills in, some stress is relieved and the broken stud will often back itself out.

[Hap Call]

I would pull the head and bring it to a machine shop. Hopefully you have a metalhead friend. I wouldn't think you have to pull the motor to pull off the head. You'll need a new head gasket.

This is the way to go. Make sure it's a reputable shop. If it is possible to repair they will have the equipment and tools to get it done right without damaging the head. Another option is to get another head, replace the head you have then have someone attempt to remove the broken bolts.

Hap

[Redman]

Update.

Thanks all,

Hello Hap.

Okay, I got the head off, and took it to the one autoparts store in town that has a machine shop. Mechaninc will look at it tommorow.

Maybe I should have taken out the valves, but I didnt. Did take out the shims (and keep them straight).

[rufus]

I just took my head off half an hour ago and only 1 of all of those snapped...aghhh.. I'll drop it off tommorrow at a shop.

[Eliseo Monteverde]

I have done this kind of job at my job shop in Radial Boring Machine drilling the broken bolt with a left hand drill.... Avoid heat all the possible to prevent distortions on the flat surface.

P.S. During this job the bike must be in the center stand and cheked with a precision level if it is possible.

Good luck !!!

[bwringer]

Well, there you go, Mark -- just rent a U-Haul for a couple of days and take it to Uruguay!


(Seriously, thanks for the info, Eliseo!)

[derwood]

I hope I'm not too late . To extract broken bolts, the best method I have found is to weld a nut on the end of the remaining stud with a MIG welder let the nut cool before you try turning it out. Yours may be in too deep for this though.Never had much luck with easy outs. Drilling out the stud and installing a thread insert is what often ends up being the final solution.

[rufus]

Ya mines in too deep as well. Time to drill and retap I bet...

[feelergaugephil]

When the head is done, GO BUY ALL NEW BOLTS for the cam covers, I think from what I remember they have "7" imprinted on top of the bolt.
Bikebandit have them in stock, DONT fit any old bolt in there.

[Redman]

Good News about my head with the 7 broken cam cap bolts.

The shop (mechanic shop at auto parts store) was able to remove 6 of the broken bolts and had to drill out 1 and install a helicoil. Charged me 1 1/2 hour labor. I am happy with that.

Got the gasket set today also. So now taking head to independant bike shop to have valve stem seals replaced.