[brett 250r]

Hi guys. I am trying to get all my cases and bearings and seals ready to put my bottom end back together on my 250r.
My problem I have is the top bolt that goes through the top of the case saver and into the cases it is the 6by 100 bolt well it is broke there is a 1/4 inch part that I can grab with players but it I'd broke where it thread into the center case half.
I have heated up the area not to hot because it is aluminum but I have heated the are sprayed with pb plaster let it sit for a day and did this proces again and I can not get it to even spin out a tuch. Any ideas would be great.

 

[Daniel370r]

You can try an easy out.

 

[Daniel370r]

Have you used one before?

 

[brett 250r]

Yes I have used them they work about half the time and I can not find one small enough for the case bolt that is broke

 

[2strokesforever]

i cant really understand what you wrote above but if u can weld another bolt to it maybe you can back it out like that

 

[Daniel370r]

They make kits of them if you get the hole drilled basically in the center should come right out I've used one on a motor bolt. I have just a 8 price craftsman set of them. If you can't get them with vice grips that is the only other way I know.

 

[TRX_hooty]

Use a sharp center punch and punch/mark the bolt as close to the center as you can get. The little indention made with the center punch helps the drill bit from walking across the top of the broken bolt. Use a small left hand drill bit to drill a straight hole in the broken bolt. Sometimes it will catch and remove the broken bolt. If you don't have access to one use a standard drill bit. If left hand drill bit doesn't work then take the proper size ease out bolt extractor and hammer it in the drilled hole snug. Hopefully this will remove the broken bolt. If these methods fail you will most likely have to drill it out.

Wrote this while everybody was posting above.

 

[brett 250r]

They make kits of them if you get the hole drilled basically in the center should come right out I've used one on a motor bolt. I have just a 8 price craftsman set of them. If you can't get them with vice grips that is the only other way I know.

basicaly what it is is the top bolt that goes through the case saver and through the first case half and screws into the other case half broke where it threads into the case half. Sorry ment to respond to 2strocks fever

 

[1986quadracer]

Sometimes you can take a little die grinder with these way small carbide dental bits almost and cut a small groove in the top of the bolt and use a flat screw driver to turn the bolt out. I don't even try anymore and just grab a welder. Clean it up very well. Put cool cloth around the work area. Work slow. And tack a washer and nut on/in there. With the motor on the side. Take your time. Thread a bolt in, tack it, turn it out. A wire feed is nice

 

[acecarlos]

i cant really understand what you wrote above but if u can weld another bolt to it maybe you can back it out like that

If possible weld a bolt and extract...x2

Use a sharp center punch and punch/mark the bolt as close to the center as you can get. The little indention made with the center punch helps the drill bit from walking across the top of the broken bolt. Use a small left hand drill bit to drill a straight hole in the broken bolt. Sometimes it will catch and remove the broken bolt. If you don't have access to one use a standard drill bit. If left hand drill bit doesn't work then take the proper size ease out bolt extractor and hammer it in the drilled hole snug. Hopefully this will remove the broken bolt. If these methods fail you will most likely have to drill it out.

Wrote this while everybody was posting above.

x2...left handed drill, heated cases with a small torch locally to the broken bolt

Assuming the cases are split right now an easy out (screw extractor) would be your best bet imo. If you use a standard drill bit & not a left handed one when drilling a hole in the broken bolt, work slow so that the drill bit doesn't catch & suddenly twist the broken piece & strip the threads in the case half. Hope this helps.

Worse scenario...find a good local machine shop, they should be able to drill the broken bolt out, and re-thread the hole to clean up. Or find a local EDM shop, and have them disintegrate or ELOX (Electrical Discharge Machining is EDM) the bolt away. FYI...we remove broken bolts almost daily, 99% of them we drill out on the Mill and chase the threads to clean up. Lot's of options, Best of luck...Carlos

 

[brett 250r]

ok well before i take it to a michine shop i did try to use a wasy out and it was a snapon easy out no luck it bit and then it broke. Do u think if i freez the cases that may help i have another easy out not a snap on put a crpsman should i try that

 

[acecarlos]

Try heating the area the broken bolt is in, Aluminum expands considerably more than steel, the idea is to get the case to expand away from the broken bolt, and then pick or drill out with a Left Handed drill or easy out. Freezing won't help IMO.

Carlos

 

[brett 250r]

Ya I have heated the area a few times put pb blaster on it let it sit for a few days and no luck. Heated it again put on more pb blaster tried removing bolt with vice grips while the aluminum was still hot let it soak with pb blaster again for another day drilled hole and tryed a easy out broke easy out I don't know what else I can try myself with my tools

 

[brett 250r]

I don't put to much heat on it because I don't want to warp the case I get it hot but I don't want to get it to hot. It is hot enough u can't Touch the area and the rest of the case gets warm I don't want to use more heat then that

 

[acecarlos]

I don't put to much heat on it because I don't want to warp the case I get it hot but I don't want to get it to hot. It is hot enough u can't Touch the area and the rest of the case gets warm I don't want to use more heat then that

Smart move, dont over heat the cases, your approach is correct. Look at post #11...not what you want to hear, however, if everything else fails, might havento find a local machine or EDM shop to help you out.

PS: depending on the broken bolt location, in this case the upper chain guard mount, you can get away without bolting the case down in that location...as a temporary use only.

Carlos

 

[brett 250r]

ya that is how iy was they broke thr bolt and just left it the cases never leaked but I am doing the motor now I just want it right the furst time. I find if I takd my time do all the prep work get all my parts ordered anf together then reassemly uhh s as lot better

 

[acecarlos]

Good for you, do it right and be done with it. Might be time to find a local machine shop to help you out....one option.

Carlos

 

[1986quadracer]

If it is kinda loose take a q tip with acetone and clean it and maybe try to carefully epoxy something to it if you don't have access to a welder.