broke alternator mounting bolt updated

[matt]

So I was trying to install trans covers have to remove top bolts in alternator.  Outside bolt would turn a couple and bind up. I loosened the other two kept spraying the bolt and from small thru hole working bolt back and forth. Yup it broke I believe flush with trans. Anyone do this yet? How did you get bolt out?

Matt

Got bolt drilled and tapped,  was able to drill bolt and use original threads. Very happy.

[gordonv]

Hopefully someone will correct me if I'm wrong, but I think someone said this also happened to them, and they just ran it with the 2 bolts in.

I see no real torque on the outside of the alt, so do not see why it wouldn't be fine.

[Chrisj CMA]

For future reference.  Don't know if you did this little step but it helps.   When you need to remove the alternator, warm up the engine some. Then, when you get the socket on the bolt tap on it with a hammer a few times. This helps to bust loose the hold any corrosion may have on those threads.

[matt]

Well bike still in storage cannot run it. Did tap on bolt. Wont have bike home till next month. Thats when I can try and remove broken bolt.

[Bone]

My alt. is running with one missing mounting bolt. I loosened the first bolt. Started to apply pressure to the next and it snapped soon as I applied pressure. One of the guys told me not to worry he's run that way it will work. I looked at my maintenance log that was 04/2012 not a sign of change with the alternator. Believe the torque on those bolts is 22 lbf. with it snapping so easily I was afraid I could make a mess of the mounting area and quit trying to remove the broken bolt.

[garyheskett All 49 x 3 st.louis]

Matt,  As Bone just stated,  I broke one bolt (sitting on the bike, the top left bolt) several years ago. About a year or two ago, I changed the alternator. Still have that broken bolt in there. Been so long ago, I've almost forgotten about it. 175,000 miles and still going.

[F-six]

It happened to my Interstate when the dealer tried to do whatever to the alternator, snapped the outside bolt. The other two went out just fine. Then he tried to drill the broken bolt but didn't have enough room for the 8 mm drill bit. Just couldn't get the drill bit straight enough because of the frame. He ended up drilling a 6 mm drill bit and put in a 6 mm bolt. Works just fine.

[Houdini]

I've has a broken alternator bolt on my IS for almost 60K miles with no issues.

[matt]

Well in a couple weeks will take bike out of storage,  good to hear I can drive missing one bolt. When I get it home my plan is to remove alternator and see if flush or sticking out. Bolt was moving so if I drill I will probably start with a right turning bit see if bolt goes back in. Then from heat of first bit going to use a left bit and see if it comes out. But then again its been a while but when a manifold bolt on car/truck would brake in aluminum head I would get a nut welded to stud and turn out stud. Might go this route.

[oldsmokey]

I've had luck building a bubble in tight areas, and getting good sharp vise grips on it.

[Bone]

If you are pulling the alt. check the brushes for wear they have limit lines. They have to be changed 50k on average mine were at 90k and still above the wear lines but I changed them at my age I will hit my wear limit before the new brushes I installed

[dalai-lama]

My top left alternate bolt broke.  I used a series of drill bits that I cut with a 90 degree drill and drilled it out.   Filled the hole with JB Weld and then tapped it.  Been that way for about 90K miles and still is good.  I just took the alternator out last weekend and changed the brushes at 140K.  Did them prevous at 80K and they were not at the wear bars then and were not at this time either.  

[matt]

Bump