Snapped Bolts

[Julio A.]

I have a set of the extractor bits here but I don't know how to use them properly. I snapped a cheap aluminum bolt on the R65, it's the screw under the headlamp bracket.

[Bob_Roller]

 Is this bolt threaded into the lower triple clamp ?

First off, can you tell if the bolt broke due to be overtightened, or from the bolt being seized due to corrosion ?

If the bolt is corroded into the triple clamp, do not use an extractor, you will just break it off and compound your problems .

First thing I would try, is to get a left hand twist drill bit of the correct size, try drilling the bolt to see if it may come out on it's own .

If not get penetrating oil on it, let it sit for a day or two and try drilling it again .

I would suggest taking it to a shop that has experience with this, as it can turn ugly real fast if you don't get it right the first time .

[Julio A.]

I think i'll find a place who could fix it first. I am a little concerned playing around those triple clamps.

[Barry]

If the bolts in your lower triple clamp are alloy then they have been replaced at some time as the originals were plated steel. Looking on the bright side drilling out an alloy bolt will be easier than drilling out a steel bolt.  

Hope they manage to save the threads for you.

[Rob Valdez 79 R65]

And don't be afraid to go one size over, if need be with new threads tapped.
How often do you remove your instrument/headlight/turn signal panel, anyway?

And if you have to go this route, and you want to be really "clean", have both done to the same spec.

I would do that before having the hole filled and redrilled/retapped.

[size=14]Or use a heli-coil type repair.[/size]

[Julio A.]

I had to remove the front wheel to have enough room for the drill to fit. and I had to remove the windshield and headlights to gain access.
It's quite a hassle for a minor job, but at least it's done. Threads are still there

Now i'm contemplating to install the windshield back again. The original looks are good.  

[montmil]

Good on you, Julio, for getting that stuck puppy outta there. Consider yourself lucky!

Monte

[Rob Valdez 79 R65]

It's quite a hassle for a minor job, but at least it's done. Threads are still there  

I wouldn't consider it to be a minor job.  Especially considering the location of the hole.
And the fact that you were able to save the original threads makes it MUCH more worthwhile!

What did you use?  A reverse drill bit?  An Easy-out?  Did you put penetrating oil on it before trying?