Broken Bolt Removal

[Solomoriah]

I've broken two bolts so far, and haven't had much luck with easy-outs. Does anyone have any suggestions as to how to go about getting these things out? One is the steering damper knob, which broke off flush with the top of the steering stem. I have successfully made a hole in it, then broke my easy-out trying to loosen it. It's soaking in atf+acetone right now.

[brewsky]

My damper knob was broken off also when I got the bike.

Also broke off an easy-out in the stub, and had to drill the easy-out out!

Then just drilled the rest of the stub out and re-tapped the threads.

It was a pain....

[G-Man]

Soaking plus heat cycling ( hot air gun) helps break the seal and let's the fluid get in there.

I often drill a hole then tap a torx bit into the hole. That often give enough purchase to get the screw out

G

[conbs]

I agree with Graham that soaking and heat cycling is a good idea before you actually start the removal process.

You might try using a small punch to tap the broken easy out back and forth sideways to loosen it up. You can even try spinning it backwards just a little. Once it is loose even just a little you should be able to grab it with pliers and twist it backwards to remove it.

You might also try some left handed drill bits to drill the hole. Flutes on the bits go backwards and you have to run your drill in reverse to drill a hole. Center your hole really well and use the biggest bit that you can for the bolt. Often, it will bite into the bolt while you are drilling and back the broken bolt right out. Drilling the center out of the bolt also seems to relieve pressure on the threads a little. Don't be afraid to drill the full depth of the broken bolt.

I have had good luck with the above, though there were a couple of failures due mostly to my impatience.

[Solomoriah]

Actually, the easy-out broke off flush with the top of the hole; I used a slender punch to drive it on through the bolt stub.

I'll try heat-cycling a bit more; I've been using a propane torch, applied briefly, as I don't have a heat gun. I picked up a new, beefier easy-out (I think I had the wrong size in the first place) and am hopeful it will work for me.

[m wentz]

Try Kroil you can buy it on E Bay. It is used in the aviation industry, mainly jet engines. It is by far the best penetrating oil I have ever used. You may have to apply it more than once and the heating cycles help. I have yet to break twist off or be unable to get something apart since using it. Each and everyone I have loaned a can to has been amazed and is now a KROIL user. Mark

[conbs]

Not to start a debate, but I would stick with the ATF/Acetone mixture for penetrating oil. Somewhere on this site is a chart that shows it is a lot cheaper and specs out better than anything else. That has been my experience as well.