Head cover bolt drilled out

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Joined: Mon Nov 05, 2012 4:29 pm
Location: Bloomsburg, PA
Motorcycle: 1978 GL1000

Head cover bolt drilled out

Postby lmcclure136 » Mon Nov 05, 2012 4:36 pm

I know this is a horrible thing, and I feel very bad, but the reality is that I snapped off a head cover bold by overtightening it. I tried removing the broken stud with easy out and could not get it. as a last resort I got Heli col andwas able to drill it out and get the insert in there, but my hole was not deep enough, so I obviously hadn't drilled all the way through. Well, I tried to carefully keep drilling, but once I hit the end of the stud, the drill raced right through the back of the head before I realized it. Now I don't know what to do.

I hav a parts bike with good heads, I could replace it, but can I fix the one I have on the bike now? I am prepared to remove the head to be sure there aren't any shavings that got through and to do a repair, but I don't know what the ramifications of this holde are. I am trying to get over beating myself up so I can get on to solving the problem, but hopefully one of you knowledgeable people can help. I can't be the only person that has ever done this...am I?


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Re: Head cover bolt drilled out

Postby themainviking » Tue Nov 06, 2012 8:52 am

A good machine shop should be able to fill the part of the head where you drilled through, if it even needs to be done. If it is not into a burn chamber, it might be fixeable with JB Weld for aluminum. If it is into an area where a hole cannot be, like I said, a good machine shop can fix it. I had a head gasket go one time, and the hot exhaust channeled the head. A machine shop fixed it so I could not even tell it had been done.
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