One of the inner bolts broke off inside threads for tappet block and I cant drill or get it out. Anyone ran with 3 and not have any issues. At this point all I am doing is making it worse trying to get it. Would have to pull the front jug just to get any drill in there at a straight shot. Advice appreciated.

 

Try using a pick to turn it.

 

already tried that and a punch, tiny flathead. Made it worse trying a extractor. Cooling fins are too close. I used some grey rtv and will try 3. No choice unless I pull front jug. Even then still may not get that grade 8 out of the aluminum. I'll let the rtv sit overnight as I got some things to do and install my pushrods and exhaust tomorrow.

 

maybe a drop of JP weld on the end of a small allen wrench, just make sure it don't touch the case, your going to wait for rtv to dry anyway

 

I have seen leaks there when fasteners were not torqued to spec. I would not waste the time with the RTV myself; I believe it will leak at that corner. The way the motor moves and vibrates, I just don't see RTV sealing the leak.

Pull the cylinder and go at it the right way. The JB weld idea might work, if you can keep it off the threads. If there is enough thread to thread in another fastener, put a drop of JB weld, as suggested, thread in another bolt and wait over night to "weld" the new fastener to the remains of the broken one and try backing it out.

 

So far no leaks. Put about 75 miles on so far. I'll work on it over winter. Only about a month of riding left or so before done for season.

 

Good news. No disrespect intended but sometimes it is better to be lucky than to be smart. I would still make a proper repair this winter.

 

Already talked to builder about machining and headwork. Just take motor out and let them do it while apart. I did get luck so far. Good thing is cams and valvetrain sound good after install.