Snapped Off MC Reservoir Screw


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mytown
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Snapped Off MC Reservoir Screw

Post by mytown » Tue Aug 01, 2017 6:16 pm



Almost nothing left to work with. What little that is left has been tapered from trying to grab onto it:


Can what remains of the screw be removed and the part made functional?



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DWade1990
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1983 GL1100 Aspencade
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Re: Snapped Off MC Reservoir Screw

Post by DWade1990 » Tue Aug 01, 2017 7:26 pm

Only 2 ways to go from here. First give an easy-out a shot, if not, time to drill and heli-coil. Just make sure you're going in straight!

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RBGERSON
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had every year from 75 to 83

Re: Snapped Off MC Reservoir Screw

Post by RBGERSON » Wed Aug 02, 2017 7:48 am

Left hand drill, easy out, try a little heat on the body?, acetone/aft mix to help, if still stuck I'd drill it out a little bigger and tap one size over..looks like there is plenty of meat there to a go a little bigger.
HAD LOTS OF GOLDWING 75-83
NOW INTO 1500'S..RIDING A 1998 SE

FAIR WINDS,
RB

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jeffcosmo
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Re: Snapped Off MC Reservoir Screw

Post by jeffcosmo » Wed Aug 02, 2017 9:54 am

The best way is the hardest to arrange: TIG weld a nut onto the remains, then simply back it out. The heat from the welding will loosen the remains.

And if someone says this is too small of a bolt for this technique, bring him AND his money over, and we'll have a little bet (he WILL lose, I've done this before on smaller bolts).

Cosmo

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mytown
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Re: Snapped Off MC Reservoir Screw

Post by mytown » Fri Aug 04, 2017 6:30 pm

Tried putting a slot in what remained, that did not work:


Tried to drill and remove with easyout but broke drill bit off. That killed the idea of tapping a new hole for me. Next thought was to drill down and JB Weld a nut into the hollowed out area:




I tried a couple of experiments with JB welding a nut onto aluminum but was not too impressed with the results. Seemed too easy for the nut to be pulled out. So how about this? Why not just put the nut onto the screw before putting the reservoir onto the body? The nut would fall into the hollowed out area when the reservoir was put in place. That would leave the reservoir o-ring and the other screw holding the reservoir on to the body.


EDIT: Just realized that if I screw the lid on prior to installing the reservoir as above I would not be able get the lid off in order to fill it. :D :oops:
Last edited by mytown on Fri Aug 04, 2017 11:12 pm, edited 2 times in total.

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Hoosier Jack
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Re: Snapped Off MC Reservoir Screw

Post by Hoosier Jack » Fri Aug 04, 2017 10:26 pm

May be time for a new master cylinder. I had a similar problem with mine and replaced it with a Yamaha sportbike unit. I think I spent $30 on it. With stainless lines a caliper rebuild and new pads, I have the proverbial two finger brakes.

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mytown
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Re: Snapped Off MC Reservoir Screw

Post by mytown » Fri Aug 04, 2017 11:11 pm

Hoosier Jack wrote:
Fri Aug 04, 2017 10:26 pm
May be time for a new master cylinder. I had a similar problem with mine and replaced it with a Yamaha sportbike unit. I think I spent $30 on it. With stainless lines a caliper rebuild and new pads, I have the proverbial two finger brakes.
Your probably right. I'll try to secure the nut into the body with epoxy since I have bought the reservoir o-ring and new screws.

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mytown
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Re: Snapped Off MC Reservoir Screw

Post by mytown » Wed May 02, 2018 6:21 pm

I ended up securing the correct size nut to the bottom of the reservoir with 2-part epoxy:


This allowed the reservoir cap to be secured to the reservoir. The nut and reservoir were first ground down so that the nut could be as flush as possible. When reassembled the reservoir landed flush, with the nut falling into the divot I made in the body trying to get the screw out:




This left only one of the two screws going all the way into the body of the MC but I feel the reservoir is secure given how tight the o-ring is. I also don't think I compromised the cylinder or the reservoir as there seemed to be plenty of meat where I thinned them out. I used two new screws I bought from Honda but they can be gotten at a hardware store although they may have to be shortened.



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