Broken intake tube bolt

[Dino]

I was removing the kury valance covers to replace the spark plugs,and broke off the #2intake bolt. Well I carefully managed to remove the chrome intake tube,and expose the (stud)for removal. No luck!, , I heated it ,used PB blaster,and it started to move a few revolutions when ,snap, , it broke off again!. So I ground it off flush, center punched , drilled and used an easy out , but no luck !it won't come out , , I'm not sure what to do next. Should I try to drill and re tap the damn thing! Any suggestions,or tricks. and yes they were installed with anti-seize,many years ago. Any body else ever run into this. TIA

[sandy]

Might try freezing it. If you can find a can of freon or dry ice. I've never heard of Never Sieze failing before.

[3W-lonerider]

i worked on a bike last fall that the same thing happened. i hate those valance covers. but anyway..the only thing i could do was drill the whole thing out. and retap the hole to the next size up. went to ace hardware and got a new stainless bolt ,tapped the hole , remember your gonna have to drill the hole in the intake slightly bigger to. put it all togather. unless your looking really close you don't even notice the 1 bolt being bigger than the rest.

[Bagger John - #3785]

Not that this will help your immediate situation, but I take mine out twice a year. Once during winter-storage prep, and again when it's time to break the bike out for the season - this after changing or cleaning spark plugs. When installing the valances in the spring, I clean the bolts if needed then give them a fresh application of Anti-Seize.

[Patrick]

Nothing lasts forever,,  including never-seize.. Whenever trying to remove anything,, when it starts to turn, stop, tighten it, back it out again a little more each time and keep doing that..When you center drilled the hole, if its centered well, then try and drill until you just start getting into the original threads which should be about the tap drill size and then easily/carefully retap the original size.. As with any tap, only turn a 1/2 turn or so and back off to peal/break off the thread before retightening/tapping again.. If the hole is off-center then you'll probably have to heli-coil it or tap it over-size..

[6jugzz]

If u can get to it with a left handed drill (the tap drill size or .015 smaller) and pick the center real good, u may be able to back it out with the drill. Good luck!!!!

[sandy]

Dino: I just read on the Gold Wing forum that a 50/50 mix of ATF and acetone was the best stuff to use. Let it soak in and then use the easyout. They posted a study done by pro mechanics on all the popular penetrants and this was best by far.

[Dino]

Thanks for all the good ideas. I will try them all ,and let you know what works

[Dino]

Well nothing worked! I tried every  possible method to get the bolt out .I finally just drilled it out,and re-tapped the hole.  Its size m6-1.0. Be careful when taking off those valance covers.That's a lot of work just to change the plugs., ,Thanks again for the suggestions.