Fugged up Need some advice.
Road Master
Joined: Jul 2007
Posts: 1,009
Likes: 4
I have done this about 100 times as I am a mechanic and a machinist. Get the bike as high as you can and still be stable,use a drill bit two sizes smaller than the bolt size,and drill the bolt out. Start out with a small bit and keep going bigger till you get to the big drill bit you chose. Use one of the other bolt as a measuring device so you know how deep to drill. Use tape to wrap around the drill bit to mark it as deep as you need to go so you know when to stop drilling. If the bolt does not break out after using the biggest bit you chose then go one more size bigger. You can use an ice pick break the bolt out in small pieces after drilling. Be very carefull to drill straight and don't push to hard when drilling.
Let me know how this works out for you. I have had to do this alot,I have broken alot of bolts off in alot of different things and this is the way an old mechanic showed me how to do it. It has always worked for me.
Let me know how this works out for you. I have had to do this alot,I have broken alot of bolts off in alot of different things and this is the way an old mechanic showed me how to do it. It has always worked for me.
Road Warrior
Joined: Feb 2009
Posts: 1,519
Likes: 2
From: St. Augustine Florida
I have done this about 100 times as I am a mechanic and a machinist. Get the bike as high as you can and still be stable,use a drill bit two sizes smaller than the bolt size,and drill the bolt out. Start out with a small bit and keep going bigger till you get to the big drill bit you chose. Use one of the other bolt as a measuring device so you know how deep to drill. Use tape to wrap around the drill bit to mark it as deep as you need to go so you know when to stop drilling. If the bolt does not break out after using the biggest bit you chose then go one more size bigger. You can use an ice pick break the bolt out in small pieces after drilling. Be very carefull to drill straight and don't push to hard when drilling.
Let me know how this works out for you. I have had to do this alot,I have broken alot of bolts off in alot of different things and this is the way an old mechanic showed me how to do it. It has always worked for me.
Let me know how this works out for you. I have had to do this alot,I have broken alot of bolts off in alot of different things and this is the way an old mechanic showed me how to do it. It has always worked for me.
Good write up JohnnyP!! very exacting!!
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
Get the bike as high as you can and still be stable,use a drill bit two sizes smaller than the bolt size,and drill the bolt out. Start out with a small bit and keep going bigger till you get to the big drill bit you chose. If the bolt does not break out after using the biggest bit you chose then go one more size bigger.
.
.
If the drill walks,you will be drilling into the case.
I think the bolts are 1/4-20?If so in a perfect world you would go no larger than the minor dia. of .201".
But I garrantee that drill will most likely walk.
Better to start with a 3/32 0r 1/8 and see if it is close to center.
I would also use left hand drill bits.
A machine shop could fix this easily,IF the tranny was out of the bike!
Last edited by 1flhtk4me; Aug 27, 2009 at 07:35 AM.
Tourer
Joined: Mar 2008
Posts: 439
Likes: 5
From: Austin Texas
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Outstanding HDF Member
Joined: Jan 2008
Posts: 3,328
Likes: 15
From: Pacific Northwest
johnnyp has a great solution that will work but keeping the drill bit centered is the key. Add this:
Get a shorter bolt that will thread down on top of the broken piece and take it to a machine shop and have them drill a dead-center hole the same size as your starter bit. This will serve as a centering guide for drilling the broken piece. Then if you use a left twist drill (start slowly and remember to spin it in reverse) the broken piece may come out the first try. If it doesn't continue with the next size larger left twist drill. I have used methods similar to this many times and rarely need an easy-out. Then when you go to get a replacement make sure the bolt is actually shorter than the depth of the hole. Be patient and good luck.
Get a shorter bolt that will thread down on top of the broken piece and take it to a machine shop and have them drill a dead-center hole the same size as your starter bit. This will serve as a centering guide for drilling the broken piece. Then if you use a left twist drill (start slowly and remember to spin it in reverse) the broken piece may come out the first try. If it doesn't continue with the next size larger left twist drill. I have used methods similar to this many times and rarely need an easy-out. Then when you go to get a replacement make sure the bolt is actually shorter than the depth of the hole. Be patient and good luck.
Seasoned HDF Member
Joined: Sep 2007
Posts: 9,208
Likes: 374
From: Central Illinois, Between I-80 and I-74
Get a short piece of tubing (steel, aluminum or copper) that will fit inside the hole, it will keep your drill bit centered and protect the threads.
If you use a left handed bit it may come out while your drilling. If not then use an easy out.
Also set the drill for low RPMs and use plenty of oil.
If you use a left handed bit it may come out while your drilling. If not then use an easy out.
Also set the drill for low RPMs and use plenty of oil.