SuzukiSavage.com - Head cover problem broken bolt

Bubba1

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Head cover problem broken bolt
01/17/13 at 17:01:56

So I started to remove my head cover to do the plug oil leak deal, when I got to the L125 bolt I realized it was loose and had been broken off by the PO it was missing about 1/8" of threads that I assume are still down in the cylinder ! So my question is what are my options, can I drill it out ? Put a heli coil in? Will it matter that much if that bolt is missing? Please help thanks so much

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28887 L.A. California Gender:	Re: Head cover problem broken bolt Reply #1 - 01/17/13 at 17:05:41 sure they didn't put the wrong bolt in? I wouldn't try to drill it out and breaking off the last 1/8 is probably remote.
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #2 - 01/17/13 at 17:42:29 I guess that's possible? Thing is it won't catch at all so you cannot tighten it
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #3 - 01/17/13 at 17:43:11 Any chance someone knows exact length of that bolt?
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28887 L.A. California Gender:	Re: Head cover problem broken bolt Reply #4 - 01/17/13 at 17:48:40 125mm
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #5 - 01/17/13 at 17:49:56 Dang your good let me measure
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #6 - 01/17/13 at 17:50:45 Oh is that why its the 125 bolt ? Boy nothing gets past me
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #7 - 01/17/13 at 18:02:18 Well it's aprox 110mm long now and def sheared off so there's somewhere about 15mm of thread stuck down in the hole
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raydawg

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Re: Head cover problem broken bolt
Reply #8 - 01/17/13 at 21:03:26

I remove damage bolts as a living on commercial aircraft, and I can't tell you how critical it is to extract on the first try. Key is drill speed, slow and steady. You should be returning, in one piece, the removed material as a sqigly worm...if you go too fast, you harden the metal, making it more difficult to grab and ease out. I have removed stainless and titanium, its hard, but doable, and some of the areas/location I have to work leave a lot to desire. Remember, make the first bite solid and true, you jimmy it, you might have to drill it out, no fun....

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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #9 - 01/18/13 at 05:00:36 Is there something specific you could recommend like drill bit size and extractor size? I've used plenty of easy outs but never seen one that long ! Any help is really appreciated
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justin_o_guy2

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Re: Head cover problem broken bolt
Reply #10 - 01/18/13 at 08:19:24

Before any "extracting" gets done Id suggest a probe to the bottom of the hole & a measurement, to be certain theres really a piece of stuff in there.
If you have enough threads available to achieve the clamping forces you need w/o going in digging & drilling, you mite just be ahead to put a bolt in & go.

+1,... Serow...

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wambr Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 610 Russia, Samara Gender:	Re: Head cover problem broken bolt Reply #11 - 01/18/13 at 09:24:26 I am also so I think the previous owner of the most likely set a non-standard screws no need to try to extract may rest (although I don't think so) part. I think you have to leave everything as it is.
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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #12 - 01/18/13 at 09:57:54 Thing is I tried a longer bolt with same thread it will not grab at all so it can't be tightened the way it is there is def something stuck it the threads and must be near or at the top of the threads not allowing a bolt to screw In at all
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engineer

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Re: Head cover problem broken bolt
Reply #13 - 01/18/13 at 17:20:55

There may be just one damaged thread or a burr or foreign material that makes threading impossible. Justin_o_guy2 is right, probe the hole with a wire or something and make some careful measurements. If you have compressed air and some tubing try and blast out any dirt down in there.

If the hole is clear, I would run a tap through it before I drilled it for nonstandard threads. When a tap doesn't reach you can always weld a piece of round stock to the end of it. I have had some success using an old bolt with a notch ground in it. Make the notch perpendicular to the leading edge of the threads. If a thread is just bent or rolled over from a PO crudely trying to get a bolt started then the bolt might straighten it out well enough to get the good bolt started in the threads. Once the threads are clean and straightened then they will not cause anymore problems, just be very careful when tightening it.

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Bubba1 Junior Member Offline SuzukiSavage.com Rocks! Posts: 84	Re: Head cover problem broken bolt Reply #14 - 01/18/13 at 19:04:38 Will try your suggestions and then get back with you guys when I know for sure thanks
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