How to remove a broken bolt - Triumph Forum: Triumph Rat Motorcycle Forums
Air Cooled Twins Talk Discussion of Hinckley Triumph Twin related matters and topics.

LinkBack Thread Tools Display Modes
post #1 of 17 (permalink) Old 11-21-2005, 08:34 AM Thread Starter
Main Motorcycle: 2006 Speed Triple
Senior Member
Join Date: Jul 2003
Location: Dallas
Posts: 263
I had changed my engine covers a few months back and torqued the bolts accordingly.

About a week ago I notice one of the bolts on the left hand side and see one bolt missing, so i get a replacement and go to screw it in and it won't go in.
I take a look and see that the other end of the bolt is in there. It musta snapped an fell out (how I do not know)

Any way, does anybody have any suggestions on how to get the broken bolt out?

I know they make screw extractors that you hammer into the stripped head, but I am not sure I want to do that on my primary cover bolt, thinking it may screw up the threads.
faffyface is offline  
Sponsored Links
post #2 of 17 (permalink) Old 11-21-2005, 08:41 AM
Supersport 600
Main Motorcycle: 03 T100
Senior Member
thumper723's Avatar
Join Date: Jun 2004
Location: Virginia Beach, VA
Posts: 185
Other Motorcycle: 1982 Honda CX500 Turbo
Extra Motorcycle: 1998 Yamaha YZ400F
Take the cover off, you may have enough bolt showing to grab with visegrips.

If not, try tapping it counterclockwise with a small sharp punch.

If that doesn't work, carefully center punch the bolt, and carefully drill it out with a drill just smaller than the root diameter of the threads, leaving a bit of "fudge factor" that you may not be dead center. I use easy outs as a LAST resort.

Support Navy Search and Rescue. Get lost. (or live below sea level)
2003 Triumph Bonneville T100
1982 Honda CX500 Turbo
thumper723 is offline  
post #3 of 17 (permalink) Old 11-21-2005, 09:33 AM
Main Motorcycle: 2004 Bonneville America
Senior Member
Bryan's Avatar
Join Date: Mar 2005
Location: Turlock California
Posts: 1,349
Other Motorcycle: 1979 T140E {Bonneville}
Extra Motorcycle: 89XS650,76 T140V
s Thumper723 has said, easy outs are a last resort. If it comes down to that try to grind a flat surface on the top of the bolt so you can center punch it right in the middle. Use aluminum foil to cover all oil soaked parts under the cover to keep filings out.

If at first you don't succeed destroy all evidence that you tried.
Bryan is offline  
post #4 of 17 (permalink) Old 11-21-2005, 11:12 AM
Formula Extreme
Senior Member
Join Date: Jun 2004
Location: A-Town, MidCal
Posts: 873
Another trick, If after you remove the cover there is a bit of the bolt showing, you can cut a slot in the top of the bolt for a flat blad screwdriver. I'd use a dremel & cut-off wheel, or a hacksaw (less precise).

If you do decide to "drill ot out" be very cautious.. if you drill the threads in the case out, it could start gettin real expensive, real fast.

I just re-read your post and noticed it's the clutch cover. Before you remove the Clutch cover, read this:

from the NTBF:

Once again, I've learned something the hard way. Story of my life...

Then I get to the clutch cover.. the bastich!. I removed the clutch cable, then the shifter, and then all the retaining bolts. I tapped it with the mallet to break it loose, and once it did, I tried pulling it free. It didn't want to come. Little did I know that the first thing I should have done was to remove the rubber breather hose from under the carbs where it goes into the backside of the inner primary cover. By muscling it, I broke the fragile aluminum tube that acts as the crankcase breather - *****! The tube is pressed in, so I'm not sure how to get it out. Regardless, from what I've been told I can't buy just the breather tube assembly, so this may end up being a very expensive lesson indeed.

Bottom line - if you ever have a need to remove the clutch cover, the first thing you need to do is to remove the breather tube from where it's attached to the primary under the carbs. It's really an easy job - if you know what you're doing and if you don't Gorilla grip it.

Ka-Ching!!! $$$

One more lesson learned... the hard way.

Chris in NC
My advise, Get a Shop Manual FIRST!

Luck, Cyn-

Cheers y'all, Cyn-
Experience is a cruel instructor...
First you take the test,
then you learn the lesson!
Members Album
CYNCRZR is offline  
post #5 of 17 (permalink) Old 11-21-2005, 11:26 AM Thread Starter
Main Motorcycle: 2006 Speed Triple
Senior Member
Join Date: Jul 2003
Location: Dallas
Posts: 263
thanks for the advice.... I'll take the cover off and assess the situation. I have taken it off before and when i did i read that thread that talked about the breather hose : )
faffyface is offline  
post #6 of 17 (permalink) Old 11-21-2005, 12:42 PM
Grand Prix 250
Join Date: Apr 2005
Location: Kingman, AZ
Posts: 75
Send a message via Yahoo to azvinny1971
before I use an easy out I like the weld the nut to the broken bolt method. If you have access to a mig welder that is. the heat usually loosens hard to remove bolts also.

If I agree with you, we would both be wrong!! Vinny
azvinny1971 is offline  
post #7 of 17 (permalink) Old 11-21-2005, 02:34 PM Thread Starter
Main Motorcycle: 2006 Speed Triple
Senior Member
Join Date: Jul 2003
Location: Dallas
Posts: 263
yeah, but my fear is that it wont be sticking out...
faffyface is offline  
post #8 of 17 (permalink) Old 11-21-2005, 02:58 PM
Main Motorcycle: Triumph Bonneville
New Member
Join Date: Sep 2003
Location: Nova Scotia, Canada
Posts: 11
Not long ago, I snapped a bolt while trying to remove the front sprocket cover. Tried loosening fluids such as Liquid Wrench and vice grips on the 1/2" or so remaining stump. Didn't work. Took the bike to a local mechanic who tried some other fluids as well as a heating / cooling process. Only succeeded in removing what was left sticking out. Eventually took it to a welding/machine shop. The guy, who really seemed to know what he was doing, had it out in 10 mins, at a cost of about $30. After welding a nut into/onto the old bolt, he applied some heating/cooling and it came right out with an air wrench. His advice: never, ever try to remove those bolts again without first tapping the end and then using an air wrench. Failing that, use a socket on an impact driver. Never try to do it with hand / arm pressure alone. Hope this helps.
TimSF is offline  
post #9 of 17 (permalink) Old 11-21-2005, 04:34 PM
Grand Prix 250
Join Date: Oct 2005
Location: Houston Tx.
Posts: 44
Does anybody know if the bolts go through and sort of cleaning or coating process? The reason I ask is because we had a problem at work with the heads popping off bolts on some of our products. The problem turned out to be something called "Hydrogen Embrittlment".
MotorTex is offline  
post #10 of 17 (permalink) Old 11-21-2005, 07:53 PM
Posts: n/a
I recently snapped off my shift knob flush with the gear shift arm. The stub was easy to remove with a screw extractor.

To use a screw extractor you drill a small pilot hole in the center of the broken bolt, then screw the extractor counter clockwise into that hole, then use a small crescent on the extractor to back out the stub. Its dead simple, and the extractor kit will tell you which size drill bit to use for a given extractor.

I've tried the other methods over the years, cutting a slot, trying to grab the broken stud with vise grips, etc., none of them work nearly as well as a screw extractor kit. I generally use an extractor whose pilot hole is 1/2 the diameter of the broken stud.

The only problem I can see is if the bolt was installed with a large amount of torque. In that case, you may be stuck with drilling and re-tapping as a last resort.
Sponsored Links

Quick Reply
All posts must adhere to Forum Rules

Register Now

In order to be able to post messages on the Triumph Forum: Triumph Rat Motorcycle Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter your valid email address, that can receive an automated confirmation message. Otherwise, you won't be able to gain full access.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
Broken bolt in upper tripple tree zmilin Air Cooled Twins Technical Talk 3 04-06-2007 10:26 AM
how critical is this broken bolt? johnnypence Classic, Vintage & Veteran 6 03-26-2007 11:33 PM
broken bolt thx1158 Tiger Workshop (archive) 3 06-27-2006 11:50 PM
Broken valve cover bolt zimtok Maintenance & Workshop Talk 2 12-06-2004 02:53 PM
Broken Headlight/Turnsignal Housing Bolt robtroll23 Hinckley Classic Triples 0 06-10-2004 07:17 PM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are On

For the best viewing experience please update your browser to Google Chrome