Broken bolt hell - Where do I go from here?

[Howie]

Alum is a good idea, but hard to do with the bike vertical.  If someone has a portable tap zapper that is a possibility.  A welder is the best shot, assuming you already tried tapping the easy out with a small punch.  The carbide drill is not that easy since it will try and walk around the easy out.  If you want to try that fabricate a guide to bolt to the case. 

[RAT900]

maybe a dremel with a small cutting wheel to carve a slot in the face of the broken-off reverse tap....??

reversible impact tool with a flat head screwdriver bit?....

back the hardened steel piece out of the hole

and drill out the screw shaft for helicoil or suitable replacement threading device

[Javamoose]

Do a search on DISSOLVING a steel screw or tap thats broken off flush and stuck in an aluminum hole.  Basically use an acid solution using nitric acid or Alum (aluminum potassium sulfate) and water solution, which will dissolve the steel, and leave the aluminum intact.  You'll need to create some sort of reservoir (I'd try modelers clay) to hold a small amount of the solution above the screw, then watch the steel bubble and fizz.

Edit: here's a good thread:
http://www.advrider.com/forums/showthread.php?t=547390&page=2

Jeff

+1 On this idea.  Worst thing that could happen from trying this is losing some time.  If it doesn't work, try some of the more aggressive ideas posted.  But really, try this first. 

[mendoje]

All it takes is a little creativity.  I mentioned using modeling clay to fashion a makeshift reservoir to hold the solution on the screw head while the bike's vertical.  You could even epoxy a small section of aluminum, glass, plastic tubing, even a "bendy" straw, and after the screw has fizzed away break off reservoir and clean up any residual epoxy.  Or just take the tank off, lay the bike on its side on top of a mattress, and start applying the solution with an eye dropper.  So many ways to accomplish this...

Alum is a good idea, but hard to do with the bike vertical.

BTW, it might take a few days for the whole process.  And likely you dont have to wait for the entire screw to dissolve.  The solution will seep into and attack the screw threads first.  That might be all it needs to loosen up or even pull out.

[tommys67]

WRAP-UP...

I had a local mechanic take a look at it, and based on the size of the bolt, the dimensions and use of the case, he advised to ignore it, make sure the broken bolt remnants were BELOW the deck of the case, and just be a little liberal with the RTV.

Sure enough, worked like a charm.  I was ALSO a lot more practiced in getting the case cover back on this time.

However...The clutch was hard to engage, and then when it did finally engage, it slipped out of gear at around 4,500 rpm... 

I took it to the selling dealer yesterday.  Hopefully this little nightmare is about over.

[jerryz]

Spark erosion will remove it , but the case will have to be off the bike to do it.

[Bill in OKC]

I have a 35 year old aluminum head with a broken screw in it.  I've been afraid to touch it, thinking I'd break a fin if I used too much force on it.  I did a search.  Tonight I'm going to stop by the grocery store and buy some alum and see what happens.  Thanks for this thread!