I screwed the pooch. on Starter rebuild.

[velvetrider]

I am going to be positive about this f up. I have had Blackvelvet for 19 years ,, I don't ride a lot she only has 85K, on 83 GL1100. Very slow to turn over for about a year. I knew starter rebuild or sell the old girl.. but I couldn't bring myself to part with her,,, so in I went after reviewing 15 pages of posts on the "rebuild your starter motor" here.. After 4 hrs. I had removed shifter, engine crash bars, Lowered muffler to gain access to the 8mm, forward bolt. It simply would not come loose. I can tell you at 72, patience is not a virtue. Instead of soaking it with Kroils, for a day or two, then going back to remove the stubborn bolt, I simply snapped it. Not sure about trying 'easyout' cause it is still difficult to get to. Just fixed a drink and shared my stupidity with you guys.

[Earl43P]

Sorry to hear your troubles.
Is there any bolt shank protruding such that you (or someone) could weld a nut to it?

Personally, after removing the starter, if I found any bolt protruding, I'd heat it and hit it with penetrating oil repeatedly.
https://www.lowes.com/pd/Turbo-Blue-Tur ... 1003176880
Then I'd work it back and forth with good vise-grips.

Please keep us advised how you proceed.

Continue on with your starter maintenance, remount it and determine whether it operates well enough without THAT bolt.... RIDE IT.

(did I REALLY JUST TYPE THAT? Yes I did because that's EXACTLY what I'd do).

[velvetrider]

Earl,, you are a jewel. Thanks for the reply. Nope nothing proturding,(sic),lol,, Yea I am going to try the easy out method, but I have little hope. I have been using KROILs penetrant,, very good stuff.
and will give it a shot this evening. I think I will go to a local electric rebuilder instead of pushing my luck. I will go ahead and adjust valves ect while Blackvelvet is on the stand. I will keep you posted.

[Rambozo]

If the bolt was seized enough to snap off, I would not advise an "easy out" ( a misnomer if there ever was one). They can only apply much less torque than the original head. So the only place they work ok is if the head is rounded off or something like that. They are hardened and very easy to break off, especially if you don't use them all the time. When I worked at a machine shop I removed tons of broken easy outs, and hundreds of broken bolts. It is a lot easier if the broken bolt is unmolested. With the right tools and fixtures it is easy to drill out a bold exactly on center, still on the bike. However, if someone has already drilled an offcenter hole, then it almost always requires being put into a milling machine to mill out the piece.
Kroil and some heat and shock might do the job. I would try to get it to turn even a little with a punch, then you have a chance. Otherwise I agree leave it out if possible or take it somewhere. If you know you don't have the patience, that is not the job for you.

[velvetrider]

Too late Rambozo, Rambozo, I just saw your reply to my post, as I quite working on it after snapping the EZ out off in the block. It would be comical if I really didn't love to ride so much. I thank you for your ensight. I can tell you that you are 110% correct. I had a decent pilot hole about 1/4 '" in. Now I don't have sh.. .
You can pass this note along.. Many thanks to you and the gang.

[Rambozo]

Thanks to technology there are now tools I could only dream of when I was at the machine shop.
We didn't have an EDM, at the time they were giant expensive machines. But as a last resort we would send broken tap removals out for that process.
Now they have portable units that could even work with the engine still on the bike. Hell you can even buy one off Amazon. I guess the future is now.
Find a shop with one of these and bob's your uncle.
https://www.amazon.com/dp/B01LMYQEX4/?tag=goldwingdocs-20

[velvetrider]

Rambozo, you da man. Thanks I am sure I can find one around here somewheres. Mooresville, where I live is the home of NasCar. I guess I just refer to it as an 'EDM' machine ? Thanks again, I will keep you guys posted,

[AZgl1800]

Dawsonville, GA has a heavy influence in NASCAR, there is a big museum there that I have gone through.
There is a hamburger shop there, across the street from the museum, with a huge amount of memorabilia on the walls.... ate many a burger there.


from https://en.wikipedia.org/wiki/Dawsonville,_Georgia

Auto racing

The city's community is known in auto racing circles for its long tradition of involvement in the sport; many racing skills originally developed as a consequence of moonshine activity in the area. Dawsonville celebrates this every October with the yearly "Mountain Moonshine Festival".[10]

Dawsonville is the home of retired NASCAR driver Bill Elliott, who won the Winston Cup championship in 1988 and was inducted into the NASCAR Hall of Fame in 2015, and his son Chase Elliott, who won the 2020 NASCAR Cup Championship and who currently races in the NASCAR Cup Series. Bill Elliott's nickname is "Awesome Bill from Dawsonville".[11] The city hall has a racing theme as well. Following a significant racing accomplishment made by Bill or Chase Elliott, such as a win, the siren on the Dawsonville Pool Room near the city square goes off to let the town know.

[JoBoy68]

My starter the rear bolt broke. I tried everything to get it out from easy outs to heat and even chiseled a screw slot in the broken bolt
and none of it worked. I had slipped with the drill and put a hole in the case, I noticed the rear bolt hole on the starter was elongated. so I put the old starter back in to check to see if there was room for another bolt there was not. I noticed when I put the old starter back in the shape of the starter nose and the O ring oil seal, with no bolts the stater was in the case solid. I filled the hole with J&B weld putty. rebuilt the old starter it lasted a week got a new starter, so with a patched hole in the case and one bolt on the starter, I am on my 3 rd season with this patch and have had zero problems

[velvetrider]

I am waiting on the brushes from Honda,,$18. and a few other parts,, like a seal kit for the left front brake caliper. Then a quick rubbing and sanding and I have 2 packs of J B Weld. Then off to the races, I prey. Thanks man this is very encouraging. Geoff.

[velvetrider]

The saga continues. I am still waiting for the points to arrive, from Cycle Parts Nation. In the meantime I Removed the points plate. After discovering I would destroy the + lead if I continued to try and remove the armature, I ordered a new starter from Amazon, about $90. It arrived 4 days later. It came a week faster then they said. I checked that it did run.
They sent it with a new starter gear. I affirmed the gear was splined correctly with my old starter.
I am opting not to use the new gear however, I think the timing/starter chain has a wear pattern established on the old gear and I do not think it wise to change to the new starter gear supplied.
Does anyone have a different idea about this ??

JoBoy68 Commented he used J & B Weld epoxy, to fill the front broken bolt spot on the starter, and he is on his 3rd year. I am going to do the same. Again, I am shooting in the dark here. I am going to place the starter after putting it on the side stand to get it in. Then J&B Weld and let it sit for a day.
I am still open to suggestions, I could not find an EDM machine to extract the broken 'EZ out' {should be called "unEZout"} which did not require me to remove the engine. You guys, all roc, and your help assures you a spot in riders heaven at some point way distant in the future.