broken bolt help

[80GS750]

ok, well i broke the one studd off flush..... i have a hole drilled through it but its off center a little.... one bolt i havent touched and the other i got a good hole drilled out but i just broke off a drill bit inside and its stuck....

a few questions....

how long and how hard is it to remove the head? how much are the gaskets? what will it cost to have the holes fixed? how long until i get the head back on and ready to run again?

i have no manuals.... and no experience with this type of engine, but i am a decent mechanic and am good with my hands, just bad with broken bolts...

thanks guys....

the other option is to just drill them out oversize and helicoil it... i didnt pay much for the bike, so it reallly doesnt matter to me...

[Clone]

Get your buddies truck and take the whole bike to a machine shop. They can tack a rod onto the stud and then screw it out. Figure $10 per stud, it might be cheaper to just pay for an hour of shop time. i took an entire 3.9V6 to a shop and left it on the workbench. Came back the next day and picked it up after they removed the two broken studs and charged me $10 because i just left it there so they could do it in a down moment.

[tconroy]

ok, well i broke the one studd off flush..... i have a hole drilled through it but its off center a little.... one bolt i havent touched and the other i got a good hole drilled out but i just broke off a drill bit inside and its stuck....

a few questions....

how long and how hard is it to remove the head? how much are the gaskets? what will it cost to have the holes fixed? how long until i get the head back on and ready to run again?

i have no manuals.... and no experience with this type of engine, but i am a decent mechanic and am good with my hands, just bad with broken bolts...

thanks guys....

the other option is to just drill them out oversize and helicoil it... i didnt pay much for the bike, so it reallly doesnt matter to me...

'You should have drilled right thru the middle of the broken bolt and thread it for a 6mm. This is a fix that works and doesnt cost much if you want to ride and not hassle with getting the original bolts out till winter when your not riding.

[80GS750]

man thats a good idea... never would have thought of that....

crap.

my dad is coming over tomorrow to see if we can drill the remainder out... then i think we will end up helicoiling it..... crap..... again

[CA180]

Good luck drilling through a bit. I broke a bit off in an exhaust manifold on my 350 and tried drilling it... Needless to say, i've got headers now.

I'm a big DIY guy, but i'm going to go with everyone else on this one.

Take it to someone who does this on a regular basis.

I wish you the best of luck though

[80GS750]

i dont think the bit is stuck that bad, but i wont know until i really look at it tomorrow.... if i cant get it out, i will be taking it in

[terbang]

Aaargh scary stuff those broken exhaust bolts. I have now put studs into my head and have put them in with a product called 'copper slip' which is for exhaust studs. Have had some success with easy outs and the likes but you need to drill right through the broken stud which helps relieve some of the tension on it, soak in some type of penetrating oil and have a gentle, accurate and patient hand. If you snap off an ezyout then you are in for a frustrating time. Even a snapped drill is going to mess things up a bit. Helicoils will be the answer if you have enough meat on the head left after a botched stud removal.
Good luck..

[psyguy]

I have now put studs into my head and have put them in with a product called 'copper slip' which is for exhaust studs.

terbang, can you explain this in more detail, sounds interesting
what's the "copper slip"?
thanks

[Suzuki mad]

We have it here in the UK. Its a grease with copper in it. The copper stays on the bolt and won't melt or wash away so the bolt always has some lubricant.

Broken drill bit, NASTY. If its flush then its a real pain..... if you can get some pliers or the tap tool to hold it then you should be able to turn it out. You probably moved the drill while drilling the hole hence why it snapped. I suspect it was a small one.

If it won't come out and won't be drilled then its down the 'spark errosion' method. Thats a specialist machine shop. They put the bolt and bit hole under a special machine which fires electrodes at the bolt and eats it away.

Never had to use one yet.......

Suzuki mad

1981 GS1000ET
1983 GS(X)1100ESD
2002 GSF1200K1

[jimcor]

We have it here in the UK. Its a grease with copper in it. The copper stays on the bolt and won't melt or wash away so the bolt always has some lubricant.

Broken drill bit, NASTY. If its flush then its a real pain..... if you can get some pliers or the tap tool to hold it then you should be able to turn it out. You probably moved the drill while drilling the hole hence why it snapped. I suspect it was a small one.

If it won't come out and won't be drilled then its down the 'spark errosion' method. Thats a specialist machine shop. They put the bolt and bit hole under a special machine which fires electrodes at the bolt and eats it away.

Never had to use one yet.......

Suzuki mad

1981 GS1000ET
1983 GS(X)1100ESD
2002 GSF1200K1

In the states it's usually refered to as 'anti-sieze compound'. Pricey stuff, but darn well worth it.

[purplemotoman]

If they are not broke off flush you might be able to just put a nut on it.
I broke one once and just retapped the threads on the broken part and was able to tighten the exhaust with a nut.

[80GS750]

well they are all flush now..... but i have one bit broke off about 1/4" down in the hole... i didnt have time to mess with it today, i will get to it tomorrow...

[80GS750]

ok, i am throwing in the towel. i have 1 easy out broken off flush, and 2 drill bits broken off.... im taking the head off and taking it in..

i have the cam cover off.... dont know where to go next. does the chain come off? there arent any links in it that disconnect that we could see? and i only saw 4 main studs holding the head on and 1 little bolt on the front underside. what do i do next? does it just unbolt and come off chain and all? does the chain come out then the head comes off?

sorry about my ignorance here, just the first time i have ever worked with an engine like this.

thanks guys

[tconroy]

ok, i am throwing in the towel. i have 1 easy out broken off flush, and 2 drill bits broken off.... im taking the head off and taking it in..

i have the cam cover off.... dont know where to go next. does the chain come off? there arent any links in it that disconnect that we could see? and i only saw 4 main studs holding the head on and 1 little bolt on the front underside. what do i do next? does it just unbolt and come off chain and all? does the chain come out then the head comes off?

sorry about my ignorance here, just the first time i have ever worked with an engine like this.

thanks guys

Just take the bike up there.They can do it with the head on the bike.

[jimcor]

ok, i am throwing in the towel. i have 1 easy out broken off flush, and 2 drill bits broken off.... im taking the head off and taking it in..

i have the cam cover off.... dont know where to go next. does the chain come off? there arent any links in it that disconnect that we could see? and i only saw 4 main studs holding the head on and 1 little bolt on the front underside. what do i do next? does it just unbolt and come off chain and all? does the chain come out then the head comes off?

sorry about my ignorance here, just the first time i have ever worked with an engine like this.

thanks guys

Why ask? You never took anybody's advice to heart up to this point. You did what everybody told you not to do. Do whatever you damn well please.

Yeah, I know, and I really do apologize in advance. That's kind of a nasty reply, no it is a nasty reply and I am sorry. But dammit why did you bother to ask if you weren't going to listen???