Big problem with one timing cover bolt


Information and questions on GL1200 Goldwings (1984-1987)
  • Sponsored Links
tbeiler
Posts: 138
Joined: Tue Oct 18, 2011 9:25 pm
Location: Waterloo, Ontario, Canada
Motorcycle: 1986 Goldwing Aspencade,
1985 Goldwing LTD
1983 CX650 Turbo

Big problem with one timing cover bolt

Postby tbeiler » Fri Jan 01, 2016 9:41 pm



New timing belts are on, got some Mr Gasket to hold the rubber gaskets in place while installing the bolts, only to find that the outermost bolt on the LHS (when sitting on bike) is broken off inside the housing at the start of the threads. Did recall that this bolt needed some oompf to release it. I guess that snap when you crack open a bolt actually broke the thread off the bolt in my case.
So I get out my trusty drill, center punch to get the drill in center, drilled a .116 dia. hole about 1/2 inch or less into the bolt, then I needed a slightly longer drill to clear the cam wheel, went slight larger to .136 dia. It was going in not problem then it happened.
The drill broke off inside the hole, and now I have a BIG problem. Happy New Year to Me.

Any ideas, carbide or diamond drill to drill out remaining part of bolt with part of my drill stuck inside the hole. Not even sure if this is possible.

A few pictures tell all.
broken bolt as removed from bike
broken bolt as removed from bike
look closely, you will see the hole I drilled with the drill snapped off. Now what?
look closely, you will see the hole I drilled with the drill snapped off. Now what?



User avatar
Whisky
Posts: 42
Joined: Sun May 17, 2015 7:34 am
Location: Rapid City SD
Motorcycle: 1984 Honda GL1200 Aspencade
2002 Honda VTX 1800 Retro
Contact:

Re: Big problem with one timing cover bolt

Postby Whisky » Fri Jan 01, 2016 10:18 pm

I had to take a double take on the picture. it is not the right bolt? It looks like a value cover bolt and I see a timing gear witch is in the front of the bike? All I can say is get a small drill bit and take your sweet time. I had broke off some in my engine block and took a few hours and some really good bits to fix it. If you do stripe it out, you can put in a thread. get them at your napa or auto store.

User avatar
Aussie81Interstate
Posts: 682
Joined: Thu Nov 27, 2014 2:34 am
Location: Penrith Australia
Motorcycle: 1982 CX500 Turbo (restoration project)
1981 GL1100 Interstate (sold)
1988 GL1500

Re: Big problem with one timing cover bolt

Postby Aussie81Interstate » Fri Jan 01, 2016 10:36 pm

Worst case scenario - would see removal of the head and off to an engineering workshop to get the remnants of the bolt and the drill bit out.

I suppose in this situation as well that an easy-out might be used - but as a last measure only - because if that snaps off in the hole then you are indeed in a deep pile of crap

thompsoj22
Posts: 55
Joined: Sun Oct 18, 2015 8:00 am
Location: Ridgecrest CA
Motorcycle: 1986 Honda Goldwing GL1200I

Re: Big problem with one timing cover bolt

Postby thompsoj22 » Sun Jan 03, 2016 10:28 am

so perfection on a thirty year old bike cant always be expected. put the belt on install the gasket in the cover with rtv, let it cure, install the cover on the bike with rtv and the one good bolt. if your a perfectionist than rtv the broken bolt to the rubber grommet and it will appear perfect. the one remaining bolt will support the cover and down the road you go. If this seems "unacceptable" than you need to own a HD for a couple years for some therapy. At the end of two years "anything" that makes the bike roll forward will be acceptable!!!!!!!!!!! :lol:

User avatar
deanbw
Posts: 278
Joined: Sun Nov 30, 2014 2:30 am
Location: puyallup,wa.
Motorcycle: 1986 gl1200a aspencade . Honda xl600r, '68 z50, '82z50, '80cx500c, '00 klr250

Re: Big problem with one timing cover bolt

Postby deanbw » Sun Jan 03, 2016 1:52 pm

well, your a little past this point now but- I owned a machine shop for many years and when someone would come in with this problem I always told them, next time bring it in before you make it worse and never use ez-outs. unless the bolt is reay to come out awayway, those things are crap, the way they work is by using a wedge fit, either by tapered screw or tapered pound in. In both cases if the bolt is broken flush with the surface it expands the bolt making it tighter and chances are good your going to break the ez-out.
The best way to remove a broken bolt is to go to your local bolt supplier ( tacoma screw, fasten-all, ect.) or machine tool supplier and get left hand drill bits. These are great because as your drilling chances are good it will screw the bolt out before you are done drilling out the hole. If it does not come out drill the tap drill size needed and re-tap the hole.....carefully.

User avatar
deanbw
Posts: 278
Joined: Sun Nov 30, 2014 2:30 am
Location: puyallup,wa.
Motorcycle: 1986 gl1200a aspencade . Honda xl600r, '68 z50, '82z50, '80cx500c, '00 klr250

Re: Big problem with one timing cover bolt

Postby deanbw » Sun Jan 03, 2016 1:59 pm

thompsoj22 wrote: If this seems "unacceptable" than you need to own a HD for a couple years for some therapy. At the end of two years "anything" that makes the bike roll forward will be acceptable!!!!!!!!!!! :lol:


This is just mean, I would never wish that on anyone, life is too short to spend it trailering that anchor back home after every ride

User avatar
roadwanderer2
Posts: 4111
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: Big problem with one timing cover bolt

Postby roadwanderer2 » Sun Jan 03, 2016 2:14 pm

can you get to the broken drill bit with a pair of long nose needle nose pliers and turn it counter clockwise to turn the drill bit out? or is it wedged in too tight to do this.

stuart.

tbeiler
Posts: 138
Joined: Tue Oct 18, 2011 9:25 pm
Location: Waterloo, Ontario, Canada
Motorcycle: 1986 Goldwing Aspencade,
1985 Goldwing LTD
1983 CX650 Turbo

Re: Big problem with one timing cover bolt

Postby tbeiler » Sun Jan 03, 2016 7:05 pm

Anyway,today I refurbed some electrical connectors, and stuffed connectors with dielectric grease, now that all is exposed. Also cleaned up all the dirt and grime from air filter housing and repaired a cracked hose with a splice.
Im going to try as previous suggestion to grind down my long needlenose pliers and try to get that drill out.
I do have some screw extractors and not 100% if I want to try it, fully understanding that the wedge fit just makes screw tighter in the Aluminum casting. I do like the idea of the left handed drill bit, never thought of that.
When I was toolmaking we would sometimes send out items that were stuck real bad for EDM. (electrical discharge machining). Only problem with this is I have to remove the head and then find a shop that can do it for me. Have'nt removed a head yet from the GW.
Before I get to this point though I will definitely try to get that sucker out.
Wish me luck.
Thanks for all the suggestions by the way.

User avatar
roadwanderer2
Posts: 4111
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: Big problem with one timing cover bolt

Postby roadwanderer2 » Mon Jan 04, 2016 4:22 pm

hope it works out for ya. keep us posted on your progress.

stuart.

User avatar
geraldm
Posts: 133
Joined: Fri May 15, 2015 12:07 pm
Location: pumphandle Saskatchewan ,Canada
Motorcycle: 86 gl1200 Aspencade

Re: Big problem with one timing cover bolt

Postby geraldm » Thu Jan 07, 2016 11:59 am

I have broke bits the same way ..,, If you are persistent and keep worrying the drill bit with anything you can fit in there , once it moves you should be able to work the darn thing out , I have found on things with high carbon steel that I have built up usually gets to hard to redrill holes or what ever , I have used a drill bit and ground almost all the taper off the cutting end and used it as more of a scraper than a drill bit , it does work but it is a lot of fooling around resharpening the scraper and so on , Thumbs up on the reverse bit for drilling out broken stuff , it is the best way to start at it .

tbeiler
Posts: 138
Joined: Tue Oct 18, 2011 9:25 pm
Location: Waterloo, Ontario, Canada
Motorcycle: 1986 Goldwing Aspencade,
1985 Goldwing LTD
1983 CX650 Turbo

Re: Big problem with one timing cover bolt

Postby tbeiler » Thu Jan 07, 2016 1:00 pm

So, yesterday was the day I decided to go at the broken drill. Prior to, I got some used long dental picks from my brother the dentist.
I cleared out some of the chips that were holding the stuck drill in place. Working the pick in and out to clear chips for a few minutes, that broken off drill came right out. Did get a left handed drill as well, but this was 3/16, all I could get. I was hoping to turn that old bolt out when I drilled into it. Wasn't able to turn it out.I suspect that my initial hole was'nt 100% centered, but was pretty close nontheless.
This morning I went at the hole again, I used a tap drill size of 5 mm and then tapped the hole with an M6 tap, very slowly. It seemed to cut fine without issues, put lots of cutting fluid in there and backed it out a few times to clear the chips. Even trimmed down one of the 6mm taps so I could get threads all the way to the bottom of the hole.
Now all I need is a 90019-MG9-000 BOLT, SPECIAL (6X58) since mine is sheared off and not enough thread left to screw into the hole.
Now back to cleaning the electrical connectors.

User avatar
roadwanderer2
Posts: 4111
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: Big problem with one timing cover bolt

Postby roadwanderer2 » Thu Jan 07, 2016 1:22 pm

nice job getting that broken bit out. you can find that bolt on partzilla......http://www.partzilla.com/search/?q=9001 ... &x=32&y=19 or on ebay..........http://www.ebay.com/itm/New-OEM-Honda-S ... pU&vxp=mtr

stuart.

tbeiler
Posts: 138
Joined: Tue Oct 18, 2011 9:25 pm
Location: Waterloo, Ontario, Canada
Motorcycle: 1986 Goldwing Aspencade,
1985 Goldwing LTD
1983 CX650 Turbo

Re: Big problem with one timing cover bolt

Postby tbeiler » Sat Jan 09, 2016 10:34 pm

Tried the dealer for the bolt first, not available with Honda Canada. Thought I would have to order from flea bay and pay some duty and shipping, then after work today went to local bike wrecker, and 5 minutes later got my bolt along with a few other items I needed. 10 bucks for all items and Bobs your uncle, Sally's your aunt. Timing cover is back on and snugged up tight. although I did shorten the thread length a bit since my drill was not long enough to go any deeper.
Rad goes back on tomorrow, Oh Yeah.

User avatar
roadwanderer2
Posts: 4111
Joined: Thu Aug 08, 2013 4:03 am
Location: sweetwater, Tennessee
Motorcycle: 83 GL1100A aspencade, previously owned, 1981 honda GL500i silverwing interstate, 1974 yamaha xs400, 1974 Honda cb450 twin cam, 1983 honda vt30, 1982 honda 700 shadow, 1972 cb750four, and my first bike, a brand new 1982 honda CM400e. and a new to me 1986 GL1200 aspencade SEi
Contact:

Re: Big problem with one timing cover bolt

Postby roadwanderer2 » Sun Jan 10, 2016 7:54 am

that's great tbeiler. glad you found the parts you needed to get it fixed especially at that price. hope you get it back on the road soon. i was up at my friends bike salvage yard thursday, picked up a drivers side markland floorboard in perfect condition with the heel-toe shifter for $20 bucks. can't beat that price with a stick.

stuart.




Return to “GL1200 Information & Questions”




Who is online

Users browsing this forum: No registered users and 3 guests