How to cuss up - broken bolt gearbox cover

[Riko_imp]

Okay, here goes my cuss up moment

I wanted to clean the inside of the gearbox cover and after doing this I wanted to tighten the 4 bolts....

I misread my SERVICE MANUAL and use a torque settinng of 54NM (wich is actually for the big bolt for the chain) although the service manual did not specify a torque setting for those 4 bolts.

The pictures so you know where I'm at: (click to enlarge)

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[url=https://postimage.org/app.php]screen shot windows


My bike is still in waranty but I doubt the dealer would do this for free (wich I would not blame him if I have to pay for my own stupidity) IF there is any method of unscrewing the head thats still in there?

FYI, the 3 other bolts can be used, although 2 of them were almost at the point of breaking too, as you can see on the picture, there is a narrow section you can see on 2 bolts.

Main concern, I want that freaking bolt out!


Thx everybody for any input.

[Nemo_imp]

You need the correct size bolt extractor to get the bolt out. Also, after that torque, I suggest you replace all 4 bolts.

[redbirds_imp]

You need the correct size bolt extractor to get the bolt out. Also, after that torque, I suggest you replace all 4 bolts.

I will second all Nemo has said. Hope all turns out well.

[kmoney_imp]

I would also agree with the above. As a general rule, torque spec for a 10mm bolt is going to be between 9 and 12 foot pounds and never really ever over 15 foot pounds.

[Carguy1959_imp]

You need to get a small drill bit, about half the size of the bolt to start. Take your time and drill a hole as close to the center of the bolt as possible. Then get a bolt extractor. That is all the dealer or any other repair shop will do. If you have to start off with a smaller bit and work your way bigger that is fine. The main thing is you need to drill the hole in the bolt without getting in to the metal around it. Or just get 3 new bolts and leave that one the way it is, there is nothing to leak, so it will probably be fine. Your choice. Good luck.
Also I am certain that he has learned a lesson in torque specs, just sayin...

[Elipten_imp]

Get a flat spot on that broken bolt. Center punch, then drill and use bolt extractor or ezi-out. HOWEVER if you break the removal tool off in the bolt you are really in deep poop.

So if timid about it. Take it to a machine shop or a shop with experience.

THROW the other bolts out!

[Riko_imp]

talked to my neighbour who works in a company that builts boat engines, so just to say, he has seen his fair part of bolts en mechanical stuff and tools .

He said, it can't be done.

The bolt it located TOO DEEP and the bolt diameter is too narrow!
That combination makes it nearly impossible.

You would need a long and narrow drill.
And a very very steady hand.

A precision drill guide would do the job perhaps, but how the hell can you do it when the bolt is on the bike...

To clearify what bolt I am talking about, look at how tiny that sucker is:



Its a national holiday so all dealers are closed and I'll have to wait for an answer to untill tomorrow, IF they answer.
But I'm coming to terms with the fact that I most likely will have to accept the fact that the broken bolt will remain inside...

[CIP57_imp]

Use #1 Speed Out Extractor. Will only allow you to go in 1/8 of in inch so you won't damage anything. Stay away from a drill bit if your unsure of your ability. Just make sure lefty when extracting or you'll lose the chance.

Our just get three new bolts with Lock Tite ( blue ) and torque to speck. If it doesn't rattle your good to go!!

[Lord Popgun]

If it really bothers you, couldn't you remove the cover (called a Holder, L. side in the fiche) and get access to the bolt? Item 4 on the fiche: http://www.hondapartshouse.com/oemparts/...rear-cover

Then you would have access to he bolt and it could be removed a couple of ways, including those above. Or am I missing something?

[Riko_imp]

no, the broken bit is in its own space, removeing that whole part you refer to wont change anything
and the dealer already answered on this holiday
they already ordered some new bolts wich will arrive around tuesday

saturday they would look when to plan me in their schedule

he said it should be an easy job...
curious to know how much it will cost me