Broken Shifter Bolt

[Mully]

Ok, so I didn't finish the Jackpine Sunday. Something about a stump and a gear shifter meeting each other on bad terms. The shifter bolt has snapped completely off inside the shift shaft. Can someone tell me what method they would use to remove the remaining bolt???? The remaining bolt is below the surface of the shift shaft.

Center punch the bolt, drill out the center, then use an extractor????? Never have used one, any gotchas to watch for??

 

[Patman]

Mully I would first try to use a pick to see if it will turn at all. Had to do this recently on one of the rotors on the TT when a locating screw snapped and it worked like a charm. If not then I'd look at drilling with a LEFT HANDED drill bit which might spin it out and if not will make the hole for the extractor. Just take your time and make sure it's going down the middle. If it's difficult to get the bit started use a Dremmel or similar to start a little divot, there are plent of bits that would make this easy. I've got some Easy Out brand extractors that I have used for 30 years will good results. I use a tap holder from a tap & die set to hold the extractor it's really going to depend if the bolt is stuck or loose as to what to use. I've needed the leverage of vice grips a few times. Worst cae you have to do a thread insert which is easy also.

 

[Mully]

I want a straight flute extractor, correct ??

Any recommendations on name brand ???

 

[Patman]

Well here's the thing Mully. No matter if you get a straight or twisted flute extractor if it breaks (they are hardened but brittle) you got a major PITA on your hands. I've had to extract a busted twisted flute and it sucked ( it was luck and not skill that got it out), I imagine a busted straight flute would be near impossible because instead of twisting in it basically gets pushed or pounded in to bite (about the best way I can explaine it). Before going hog wild work your way up the ladder in extraction options. Pick, lefty bit, then either extractor or drill it out. If the bolt is siezed chances are high it will snap the extractor. Doing a thread repair is a heck of a lot easier than removing hardened tool steel from a hole.

 

[Patman]

Here's some other ideas Mully.
http://www.asashop.org/autoinc/may2003/techtotech.htm

 

[Mully]

Oops! You suddenly find yourself with wrench in hand, the head of the bolt you were trying to extract bouncing on the floor, and the rest of it still in the cylinder head/engine block/suspension piece.

Congratulations - you're about to have an adventure. :whoa:

Great way to start an article............. ;)

 

[Mully]

$29.80 later I have an extractor set, one left handed drill bit, and one new center punch.


LET THE ADVENTURE BEGIN !!!!!!!!!!!!!!!!!!!!!!!!!!

you know what ??? After 37 years of dirt biking I guess I am lucky that I have never had to do this before............

 

[Senior KX Rider]

may not be a bad idea to contact your local MAC or Snap On guy

These guys seem overpriced but when you are in trouble and want to take care of your problem..............sometimes they offer a better tool :cool:

 

[Patman]

If you happen to decide the thread needs repairs avoid PermaCoil like the plague! I have used a few different kits and that one gave me more heartache than I care to recall. It should have been an easy fix on the side case of the XR but it turned in to a 2 hour battle. The tool to install it is not well designed and knocking the tang off the insert in a blind hole is a real PITA. Helicoil, Threadsert? and another I don't recall all worked really well. Some will even work in a thru hole situation which is not something many do.

Just remember Mully if you have the slightest feeling the extractor is going to break STOP!

 

[Senior KX Rider]

Just remember Mully if you have the slightest feeling the extractor is going to break STOP!

DITTO THAT :)

 

[Rich Rohrich]

... given it's teutonic origins, don't forget to goose step to the bike as you begin the work. :whoa:

 

[Patman]

Ve must egg-stract zee failed part so zadt eat ez not contamineating ze whole bike!

 

[Mully]

TAAA----DAAAAAAAAAAAAAAAAA !!!!!!!

(all times approximate)
6:03 Gather Tools.
6:05 Use dremel tool to flatten surface.
6:11 Punch starter hole for drill bit.
6:14 Drill hole.
6:20 insert extractor and realize I will never get the Tap/Dye set handle on extractor.
6:22 Ponder what to use.
6:25 Small Crescent wrench (Kentucky Fit-All) in hand begin process of removing %*&@#$ bolt.
6:26-6:27 chit chit chit chit chit it's going to break.
6:28 Bolt begins to turn. (whew )
6:30 Bolt removed and hole cleaned and inspected.
6:35 New shifter install and bolt tightened.
6:40 All Tools put away.

DONE !!!!!!

I have to ask, how much torque can one of those extractors take ?????? I mean I have broken allan wrenchs of the same size on smaller bolts.

And now on to my next project.
Making and installing new aiglets. ;)

Thanks guys.

Mully

 

[Patman]

I have no idea how much torque they can take Mully. I will say it's a lot bigger suprise when they do snap because unlike a snapped allen wrench which seems to actually twist a bit these things just snap like a piece of glass. Glad it worked out, it's really not that hard (once you snap as many fasteners as I have at least). The tough part is taking your time to get a good surface to punch it and then drilling it, after that it either works or it don't LOL!

 

[truespode]

Congrats!

My first broken bolt was on the intake of my old YZ/WR250. I was so scared using an ez out. My step-father works doing tool and die stuff and he gave me the tools and said go to it... it's easy.

Luckily I didn't break it and everything worked out until I spoded the engine during an Enduro and had to re-do the top end just 2 engine hours after doing it the first time.

Ivan

 

[Rich Rohrich]

TAAA----DAAAAAAAAAAAAAAAAA !!!!!!!

(all times approximate)
6:03 Gather Tools.
6:05 Use dremel tool to flatten surface.
6:11 Punch starter hole for drill bit.
6:14 Drill hole.
6:20 insert extractor and realize I will never get the Tap/Dye set handle on extractor.
6:22 Ponder what to use.
6:25 Small Crescent wrench (Kentucky Fit-All) in hand begin process of removing %*&@#$ bolt.
6:26-6:27 chit chit chit chit chit it's going to break.
6:28 Bolt begins to turn. (whew )
6:30 Bolt removed and hole cleaned and inspected.
6:35 New shifter install and bolt tightened.
6:40 All Tools put away.

6:41 DONE !!!!!!

6:42 Realize it's still a KTM :bang:
6:43 Drown sorrows in domestic beer, pork rinds and a bootleg DVD of Gomer in his one man softcore porn version of the musical Oklahoma :whoa:

 

[BSWIFT]

orignally posted by Rich Rorich
6:42 Realize it's still a KTM
6:43 Drown sorrows in domestic beer, pork rinds and a bootleg DVD of Gomer in his one man softcore porn version of the musical Oklahoma

Now THAT'S FUNNY, I don't care who you are!!!!!!!!!!!!!
Mully, if you want to triple your experince, I'll send you the clutch perch of my Scorpa, they're seized to boot!

 

[Mully]

[Mully, if you want to triple your experince, I'll send you the clutch perch of my Scorpa, they're seized to boot![/QUOTE]

Sure, send it right up. I figure I haven't had the full adventure untill I break the extractor tool. I have this funny feeling that old Murphy (the guy with the law) is just waiting for the right moment. :whoa:

 

[Wolf]

...b-b-b-but...it's a KTM!!!

 

[Patman]

So I wonder if the KTM flange bolts holding the plastic on my Honda are planning something? :think: