drilling out sheared bolt in 83 1100 case?


Information and questions on GL1100 Goldwings (1980-1983)
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Flyboy6
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1983 Aspencade
1997 Valkyrie
1966 Cessna 172

drilling out sheared bolt in 83 1100 case?

Postby Flyboy6 » Thu May 07, 2015 8:00 pm



so, I have the front engine cover off (83 1100 aspencade) to replace water pump, and the far left bolt sheared off - was hard to get even a turn or two, then it snapped. Tried to file the stub to get grips on, no way - far too tight. It is more or less tucked in behind frame member below rad.

I see two options - happy to have advice :

- door number one is to pull the engine, get at the front of the hole square on, and drill/helicoil. Sheesh.

- door number two, since it is the only bolt on the cover that is a through bolt, with access to back side of case hole, is to use dremel tool to clear out the stuck bolt, and replace threaded hole with a through bolt with high temp locknut on back.

I'm guessing this is two hours work, versus maybe 8 or 10?

bolt stub visible in photo just a bit high and left of centre. I know it looks like I should be able to extract it, but several houts with all the right tools, and no way.



Toronto Ontario
83 Aspencade
83 GL650i
1966 Cessna

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roadwanderer2
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Re: drilling out sheared bolt in 83 1100 case?

Postby roadwanderer2 » Thu May 07, 2015 8:26 pm

Hey Flyboy:

if you can turn the stud in even just a tad, you might be able to use either one of these stud remover tools, but first i would soak it with some PB Blaster to try to unstick it so you can turn it out with one of these 2 stud extractor tools.

if you have enough to grab onto it, you might be able to use one of these 2 tools to remove that broken stud......1st choice

http://www.oreillyauto.com/site/c/detai ... +extractor

my 2nd choice would be....http://www.oreillyauto.com/site/c/detai ... +extractor

i used the 1st choice to remove a broken stud from my front fork and it worked very well. you need at least a 1/4 inch to 3/4 of an inch to get the tools to grab onto the stud. your last 2 options would be to drill the stud out, retap the hole and put a new stud in it, or drill it out and use a nut, bolt and lock washer to go back in.

keep us posted on your progress, good luck with it.

stuart.

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WingAdmin
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Re: drilling out sheared bolt in 83 1100 case?

Postby WingAdmin » Fri May 08, 2015 9:50 am

The problem with that bolt IS that it is a through bolt, so the back end of it sticks out and corrodes. I would soak it for a day or two in repeated applications of PB Blaster, then - if it has the clearance (hard to see if it does or not), try to screw it IN - so that it comes out and can be removed from the back side instead of the front. That way you aren't trying to drag the corroded threads all the way through the hole, which is what caused it to bind up and shear in the first place.

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Flyboy6
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Re: drilling out sheared bolt in 83 1100 case?

Postby Flyboy6 » Fri May 08, 2015 10:10 am

Alas, I'm well down the road of drilling it out - a cramped and tedious job - blowing through dremel bits. I think the bolt is made of kryptonite. used lots of various penetrating lubricants, tried, over several days, moving it both ways (had a good grip on it) - nothing budging. Good observation about the odd through-hole on that bolt - I will watch for this situation in other spots.

I have the gasket face at that bolt clear now, and at moments I'm tempted to put it back together and trust the other ten bolts to adequately bind that corner down, but that's a slippery slope. I'll keep doing the root-canal on it.

Rad is now pulled, thermostat tests good, but fanswitch is (predictably?) no good. The one on my GL 650 is likewise cooked, and at the cost of new ones (100 buck a pop in local dollars) I am leaning heavily toward wiring up a panel switch and trusting my eye on the temp gage to know when to put power to it.

Meanwhile, nearly got all the gasket clear of the engine case - what a pain that it is ! Only about 10% of it came clear with the cover.

Thanks for the ongoing counsel here !
Toronto Ontario
83 Aspencade
83 GL650i
1966 Cessna

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CMReynolds1
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Re: drilling out sheared bolt in 83 1100 case?

Postby CMReynolds1 » Fri May 08, 2015 10:37 am

What WingAdmin recommends is true. I have let some very stubborn bolts sit with a type of penetrating oil soaking into it for hours or days. I will also try tapping LIGHTLY, with a tool to get a vibration in there to assist with the break up of the fowling material. Sometimes it helps, sometimes not. BUT, patience is the other part of the equation. Good Luck.
Ride Safe,
Taz


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WingAdmin
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Re: drilling out sheared bolt in 83 1100 case?

Postby WingAdmin » Fri May 08, 2015 11:08 am

Yeah, when something is bound up like that, it's the sharp raps that break them free, not the constant torque of you trying to wrench them free. My various impact tools are my best friend, especially when working on rusty cars. :)

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SteveB123
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Re: drilling out sheared bolt in 83 1100 case?

Postby SteveB123 » Sat May 09, 2015 1:40 pm

Flyboy6 wrote:Rad is now pulled, thermostat tests good, but fanswitch is (predictably?) no good. The one on my GL 650 is likewise cooked, and at the cost of new ones (100 buck a pop in local dollars) I am leaning heavily toward wiring up a panel switch and trusting my eye on the temp gage to know when to put power to it.


georgefix on eBay has them for 70CDN shipped. Used him before, great seller, if you'd rather fix it once and for all.
http://www.ebay.ca/itm/BRAND-NEW-HONDA-GL1000-GL1100-GL1200-RADIATOR-THERMO-FAN-SWITCH-w-oring-/361212448147?hash=item5419f08d93&vxp=mtr
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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RBGERSON
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had every year from 75 to 83

Re: drilling out sheared bolt in 83 1100 case?

Postby RBGERSON » Sat May 09, 2015 1:50 pm

It can also be taken apart cleaned up and reused..there was a thread somewhere with pics I'll look around.

here you go

http://www.ngwclub.com/forum/viewtopic.php?t=36052
HAD LOTS OF GOLDWING 75-83
NOW INTO 1500'S..RIDING A 1998 SE

FAIR WINDS,
RB

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SteveB123
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Re: drilling out sheared bolt in 83 1100 case?

Postby SteveB123 » Sat May 09, 2015 5:05 pm

Also, Beck/Arnley PN# 2011614. About $20.
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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RBGERSON
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Joined: Tue Mar 09, 2010 7:57 am
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had every year from 75 to 83

Re: drilling out sheared bolt in 83 1100 case?

Postby RBGERSON » Sun May 10, 2015 8:45 am

oops sorry wrong thread on the thermo fix..


HAD LOTS OF GOLDWING 75-83
NOW INTO 1500'S..RIDING A 1998 SE

FAIR WINDS,
RB


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