Broken cylinder head cover bolt

[cogsman]

Yup, my fault. Snapped the bolt as I was tightening. The pointed tip of the cylinder head cover bolt snapped off and is recessed about 4mm inside.

Any hope? I don't know if they make easy outs that small. Can i just drill the bolt with gradually increasing drill bit diameters until i get super close to the threads, essentially just eating away at the screw metal until it comes apart in pieces that i can scrape out?

[gordonv]

Yup, my fault. Snapped the bolt as I was tightening. The pointed tip of the cylinder head cover bolt snapped off and is recessed about 4mm inside.

Not sure what you are saying, a valve cover

Any hope? I don't know if they make easy outs that small. Can i just drill the bolt with gradually increasing drill bit diameters until i get super close to the threads, essentially just eating away at the screw metal until it comes apart in pieces that i can scrape out?

Isn't this what is normally done, and then using a tape, clean out the threaded hole. But this would be in a thread hole, not a free standing bolt shaft, like would be on the valve cover.

If it is the valve cover, just take the rest of the bolts off and using vise grips, turn the bolt shaft.

[John Schmidt]

I got a set of these and they have saved my bacon more than once. Works much better than a regular easy out. One end is used to drill the top of whatever is broken or won't come out, then flip it to use the other end to unscrew it. Just remember to reverse the direction of your drill. It will grab where other types won't.


http://www.sears.com/craftsman-3-pc-deck-out-screw-and-bolt/p-00952151000P?prdNo=4&blockNo=4&blockType=G4

[Pete]

I use an ice pick pointed tool to spin the rest of the bolt out.
They are usually not tight once they break and have no shoulder against something.
Put the point on one side and use a small hammer to spin it if it is snug..

[Red Diamond]

As was stated by Gordonv, just remove the cover completely, you will be able to get that broken piece out, they break easily. When you get another bolt, reinstall the cover, no new gasket is needed.

[cogsman]

I'll post a picture soon. I didn't make myself clear. The cover bolt snapped in the mounting hole. I've already pulled the cylinder head cover completely off. Now I just need to get that broken screw out of the mounting hole.

[Hook#3287]

What John suggested or regular easy outs should work.

Sometimes, the reverse easy out drill bit is enough to remove a broken bolt.

Patience and a steady hand drilling is required.

[Chrisj CMA]

I'll post a picture soon. I didn't make myself clear. The cover bolt snapped in the mounting hole. I've already pulled the cylinder head cover completely off. Now I just need to get that broken screw out of the mounting hole.

Do not bring a power drill anywhere near that bike.  You will be looking for a new head!  Use the pic method already described, the bolts are chromed, usually don't corrode in or bind.  It should be one of the easiest extractions you can face.

When putting it back together, notice those bolts have a shoulder, they should make contact with the rubber grommet first and then compress the grommet until the shoulder bottoms out.  When the shoulder bottoms out its tight, it can't go any further or it will, well you already know

[John Schmidt]

Like Chris said....so easy does it when installing those bolts. Absolutely NO TORQUE WRENCH!

[DarkSideR]

I (embarrassingly) recently did this. Please note that the valve cover bolts DO NOT NEED TO BE TORQUED! When they bottom out stop tightening!

I recovered by getting a set of easy outs from Harbor Freight tools (I couldn't find a single easy out but the kit I purchased had the correct size). I very slowly and carefully drilled into the broken bolt. I used lots of WD-40 as to not heat up the broken bolt too much. Using a hand driver I embedded the easy out, and the broken tip came out with no drama.

Now time for sticker shock as you order a new bolt 

Good luck and I hope this helps.

[cogsman]

I actually have an entire second head if I need it so the bolts are no problem. But the last thing I want to do is replace the whole head lol.

[h13man]

Try "picking" it out as suggested and if that moves it around but won't free up completely, a careful use (slow speed drill rpm) with considerably smaller LH drill bit should spin it out.

[westnek]

hi folks -I had a slight oil leak from valve cover tried to tighten bolts ;lucky I stopped before breaking and removed bolt and put another washer  on bolt so point wouldn't bottom out then tightened bolt  easy and  no leak --just a thought  ride safe all