1150: Broken can journal bolt

[crispy]

Well, I took the whole 3 day weekend and tore some parts off and started cleaning and checking what ever I could think of. Was about to put the valve cover back on and had a thought, "Hey, why don't I check the torque on the head and the cam journal bolts." (hope I never have another thought.) Started on the cam, "Hmmm, this brand new torque wrench doesn't feel right. I think I'll start a little lower than final torque setting." Well the book says 6-8.5 ft/lbs. so I figure i can't go wrong setting it on 4 ft/lbs. next thing you know, SNAP. broke one of the cam journal bolts. Now what do I do. I'm hoping that I can remove that holder and be able to reach the bolt. If not, I really dont want to take off the head, there goes my trip to Reno. Any kind words would be greatly appreciated...
What a Bummer
Thanks

[cbxchris]

I would turn the camshaft to where there is no pressure on that lobe and remove the cap. Hopefully it snapped where you get hold of it with a pair of needle nose vise grips...if not try a small screwdriver it may just turn out easily.I sure hope you don`t have to go putting easy outs or something in there but you should not have to remove the head. I`ve done the same thing before. good luck!

[saaz]

Follow the above advice. The cam bolt is a low torque item. Once it snapped it is likely that it can be easily turned out of the hole as the hole is longer than the bolt. Sounds like someone might have put the wrong type of bolt on the can cap.

[terry]

I reckon Chris is on the money here, providing it was the original bolt, it wouldn't have snapped due to bottoming out and jamming as the bolt hole is deeper than the bolt is long, it would have snapped just below the bolt head. If it has bottomed out however, it's more likely snapped at the top of the internally threaded portion, in which case your trip to Reno is looking decidedly shaky...........

If it has, you might be able to get it out as Chris described, and if that doesn't work you might be able to drill/helicoil it if it's not obscured by frame rails etc, but I think for peace of mind you might have to take the head off and do it on your bench as I'd be concerned with little bits of steel and alloy "swarf" finding their way into your engine, where they aren't gonna do it much good.

That bolt must have been pretty brittle though, 6psi is not much more than "finger tight". How much is a flight to Reno?

[crispy]

Thanks for the encouragement guys. I'm not sure how deep it goes yet. When it happened I just covered the motor with shop raqs and walked away. I'm really hoping it's accessible. The trip to reno was going to be on my bike. No airfare there.
We'll see what happens tonight after work.
Hey, how hard is it to get a hold of one of these bolts?
Shouldn't I have to loosen the whole cam? All of the blocks on this one cam, so I don't bend the cam?
Thanks again

[Anonymous]

Don?t worry in advance. The bolts are standard M6X40 mm with the washer like head. If you cant find one, use a standard with regular washer. I?m not sure of the strength of it, if it?s 8.8 or 10.9. But I?m sure the answer will be presented below in just a short while.... Other than that, listen to CBXCHRIS. This is not a big issue, to read about one go to www.biker66.com choose "my bike" and year 2003 and go down to April to read his story....A little bigger and we have been out riding together 2 times already since that. 8)

[crispy]

Well, came home from work today, after stopping by the bike shop for gaskets and a new bolt. Rolled the cam up, took off the Aluminum block. The bolt is deep enough to where I can't turn it with anything, nothing to grab. Decision time. Do I take the head off so as not to get any chips in the motor? Or do I tape and rag everything and take my chances. Gonna have to think a little on this one. I have never had any luck with Hard-Outs. I don't really trust them. Broken too many of them. Hmmmm, can I get at the back of the bolt? Or is it blind?
Any Ideas?

[Anonymous]

Broken bolt

There should be no tension on the remains of the bolt so if you can reach in with a jewlers screwdriver you may be able to catch a ridge and just unscrew the remains.

Good Luck

[crispy]

Wooooo Hooooo !!!!!!!!!!!!!!!!!
Success!!!!!!!!!!

Used a center punch, then a weeeeee tiny drill, then a little bit bigger drill, then a little bigger drill, then a center drill, then a little bigger drill, then a screw driver to try and pull it out, then a phillips head, then a torx head. The torx head did it. pulled that little sucker right out. ran a bolt through it. Woohoo back in business. I am soooo Happppyyyyy.....
Thanks for the push guys, I was about to give up and take the head off and take it into a shop. Now I don't have to. Hopefully I'll be riding again by this weekend. Knowing my luck, It'll rain.. hehehehehehe