The last time I rode my '81 XLH, the bolt that holds the timing/breaker rotor sheared off. So I removed all the points stuff and advance weights, etc., hoping that there would be enough bolt left hanging out of the rear intake cam to be able to get some pliers on or something to get it out. No such luck. It is broken off a little below the level of the cam. Any ideas about how to get this bolt out? I was thinking one of those Sears bolt extractors, but this is a really thin bolt. Don't know if there's enough meat there to get a grip. I'm thinking at this point my best bet is to try to drill the little bugger out, but I'm sure I'll bitch up the threads. Should I just start looking for a new rear cylinder intake cam and stick it in there?

 

Try drilling it out in a drill press first. if you do it, good; if not, then go for the new cam.

 

If you live in a fairly large city that has a business that sells machine tools and such, then look for a left hand twist 1/8 inch drill bit. If you do not have such a store near you then you can mail order a left hand bit from Enco.

Now the trick to using a drill on that broken bolt is to do 2 things......
First, if the bolt broken end is not fairly smooth across then try to make it smooth, at least in the center. You can use a Dremel to put a flat on it at the center os the small bolt.

The other step you need to do is make a center indentation using a good sharp center punch. Hit it as close to dead center as possible. It does not have to be exactly on center, but the closer the better.

Next, use the 1/8 inch left hand twist drill bit to begin drilling out the bolt. At some point it is going to catch and back the broken off bolt right out of the cam............pg

 

If you think you can drill right down the center of the bolt with a large enough drill bit to get an Easyout tool to fit, give it a shot yourself. Soak the hell out of the bolt with penetrant. If you are able to drill all the way through to the end of the bolt you will be able to get some penetrant working on the threads from the inside too. I'd try to do it with the cam in the bike because I am lazy and I have a lot of faith in my ability to do this sort of job. If you do pull the cam, it will make the job to get the bolt out a little easier.
Otherwise, don't mess with it and call around to machine shops to see if they are willing to give it a shot with the cam still in the bike. They do this kind of stuff often.
If you do try this yourself, use a new cobalt drill bit or some other type of very hard, sharp drill. Be careful you don't bend that drill bit while you are drilling because you will most likely be drilling at an odd angle (which makes it hard to go in straight down the bolt). The harder the drill bit, the more it will be prone to snapping off in the hole. Having a friend checking the angles while you drill (feeding slowly) will help keep you straight. Drill a pilot hole first with a 5/64" or 3/32" drill bit first then go to the size that will allow the Easyout to fit. Lube the drill bits often, especially if you are trying to drill all the way through the bolt because deep drilling is tricky. Drill a little, pull it out and squirt in lube. Do the best you can at getting the chips out of the hole while you have the drill out, before you squirt in the lube.
I do wish you luck. Take your time planning and executing this and maybe the bolt will come out without too much trouble.
However this turns out for you, use some antisieze compound on the new bolt when you install it, of course.

 

when you get the drill strarted coat the bit in grease it will grab most of the chips

 

Try this center drill the remaining bolt take a 3/8 hand impact wrench install a small allen head wrench on the impact reverse the impact (lefty loosey ) tap the bolt Maybe it will come out !!!

 

Drilling it with anything but a left hand twist drill bit will do nothing but sink the bolt deeper into the cam.
This bolt was not broken because of the threads being tight. It was broken because of the design of the bolt. This happens a lot.
If the OP does not want to try a left hand drill (we haven't heard from him since his post have we?) then he should just take some 1/8 inch bore windshield wiper hose and stick it over the broken bolt. It will probably have enough grip to simply unscrew the broken end out..........pg

 

I've seen people use locktite on these bolts Bad news !

 

Perhaps, but the bolt has a reduced diameter between the bolt head and the threads. This induces an area of stress, and is the reason they break. I have seen many break.
I'd bet a hundred bucks the broken bolt is loose in the cam........pg

 

i have no experience with this specific bolt but alot of times you can take a shortcut and use a flathead screwdriver/chisel and a hammer and hit directly on the broken bolt to make a mark on the edge of it and then place the screwdriver/chisel at an angle and with a few solid taps alot of times it will come out.