ghostman
Expert Class
Posts: 456
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posted August 19, 2008 08:04 AM
I Did Something Real Stupid
Yesterday I decided to replace the clutch steels and fibers. To my surprise, the fibers looked really good. The steels were a different story.
Anyway I made the mistake of trying to work on the bike while my four nieces were visiting.
Everything was going well; almost too easy, except a little hassle with the plastics . . . . .until . . . . .!!!
The oldest two decided to come out and keep me company.(AHHH HELL!!)
With the combination of unwillingly having to hear about everything that happened this summer, and keeping the little-one out of the oil pan, the frustration of dealing with these DAMN plastics, and the wife coming out every two minutes asking me if I needed help, I started losing focus!
DAMMIT MAN!!!
Anyway, I proceed to put the pressure plate back on and replacing the springs. I grabbed the BIG torque wrench through all the confusion(AHH DAMN); set it to 6.5ftbls and started crankin'. (Remember, by this time I was being bombarded with useless teenage drama and I felt my brain going numb.) It didn't dawn on me that I had been cranking for a long time.
So to say, my torque wrench had not been used in a long time and I found that I had ceased . . . . . . The Hard Way.
Yep . . . I snapped the bolt head off. The spring fell right in my lap.
SON OF A COCK-EYED BITCH!!!!!!!!!!!!!!!!!
Soooo . . . . . does anybody have any suggestions on tools and techniques to use to get the bolt out?
Also how smart would it be to use a zinc coated Hardware Store replacement bolt?
The reason why I'm asking is because I'd have to wait until the end of the week to get the black stock ones from the dealer.
Any help would be much appreciated.
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shane661
Needs a life
Posts: 11494
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posted August 19, 2008 08:13 AM
If the bolt is flush you will need to use a screw extractor. You will have to be careful where the shavings from the drilling action wind up. Fortunately, once you get a good grip on the bolt it should back out pretty easily.
As for the replacement bolt, I would be concerned about proper size and thread pitch. A local dealership should have a good, generic replacement bolt to replace the stocker. I am not certain of the grade of bolt used for the springs, but I imagine they are pretty stout.
You may just go to the service department of the shop, with one of your good bolts, and see if they can take care of you.
Shane
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Superman T
Pro
Posts: 1831
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posted August 19, 2008 08:15 AM
Damn ghostman, that sucks!!! Do you have any of the bolt's shaft showing?
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ghostman
Expert Class
Posts: 456
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posted August 19, 2008 08:25 AM
quote:
Damn ghostman, that sucks!!! Do you have any of the bolt's shaft showing?
It broke of about 3/4 of an inch from the head.
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lietoome
Needs a job
Posts: 2033
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posted August 19, 2008 08:33 AM
 Edited By: lietoome on 19 Aug 2008 09:35
Damn....not good. Good luck with that one. Did that to two of my sprocket cover bolts. Not sure how I will fix it.
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1badzx12r
Needs a life
Posts: 8321
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posted August 19, 2008 09:10 AM
ghost dumbazz twice
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Superman T
Pro
Posts: 1831
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posted August 19, 2008 09:29 AM
Ghostman- pay no attention to 1badzx12r,he/she chimes in only when there's something negative to say. Never anything of substance and CAN"T spell worth crap. If you read most all of his/her threads, it will be filled with negative comments and terrible grammer.
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shane661
Needs a life
Posts: 11494
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posted August 19, 2008 09:36 AM
quote:
quote:
Damn ghostman, that sucks!!! Do you have any of the bolt's shaft showing?
It broke of about 3/4 of an inch from the head.
Is any of the bolt sticking out to where you can see threads? If so, how much?
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ghostman
Expert Class
Posts: 456
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posted August 19, 2008 09:47 AM
Edited By: ghostman on 19 Aug 2008 10:53
Have to check. I was kinda in shock at the time. I just put the clutch cover and master back on and went into the house. The girls never stopped talking. Gotta love'm. 
SupermanT, I'm used to it.
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shane661
Needs a life
Posts: 11494
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posted August 19, 2008 09:57 AM
Edited By: shane661 on 19 Aug 2008 11:00
If there is some bolt sticking out, you can likely get it with vise grips.
.
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1badzx12r
Needs a life
Posts: 8321
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posted August 19, 2008 01:05 PM
quote:
Ghostman- pay no attention to 1badzx12r,he/she chimes in only when there's something negative to say. Never anything of substance and CAN"T spell worth crap. If you read most all of his/her threads, it will be filled with negative comments and terrible grammer.
and Suckerman T is a loser ..
SO whats new
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1badzx12r
Needs a life
Posts: 8321
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posted August 19, 2008 01:07 PM
Edited By: 1badzx12r on 19 Aug 2008 14:11
well ghost you get a ez-out yet to get the bolt out ...you can get a whole set with drill bits from ACE hardware for 20.00 ....
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obba
Expert Class
Posts: 455
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posted August 19, 2008 02:54 PM
Be real careful with cheapo ez-outers. Cause they can snap and leave you in a worse position than before.
1) Get good quality Ez-outs. Maybe borrow a couple of pieces from the local bike mechanic.
2) Use a centre puch to make sure you get DEAD centre for the drill.
3) Use a big as possible (within reason), EZ-out bit size - the thinner = more snappyer.
4) If you can heat up the surrounding area - Hairdryer maybe or blow torch on a low flame. This will expand the metal very slightly more than the bolt, as the bolt will be (I think), of harder material.
Another way is.
1) Centre punch the bolt.
2) Drill a hole 2mm smaller than the bolt and about 5mm deep.
3) Heat the surrounding area if possible.
3) Get a flat head screwdriver and 'tap' it into the new hole - how hard you tap is up to you  and undo it if you can.
Another way (has worked in the past for me).
If you have good diagonal access to the top of the bolt. With a small flat head screwdriver - chisel? tap (hit), the bolt (top left quarter), diagonaly at about 10-11oclock in a downwards undo direction (if that makes sense!!!).
If it starts to move/turn, then you should have no hassle using this nick to slowly work your way around - it's just a hassle as the bolt comes 180degrees around...
Good luck.
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warbird
Needs a job
Posts: 2739
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posted August 19, 2008 03:12 PM
When you buy your easy out/outs........get good ones like said above. But buy left handed drill bits. You just might get it turned out if the drill bit gets a good bite. Be sure to center punch like said above. Go slow...........and come back to this thread if you need any more help............ 
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I'd Rather Be Roadracing.
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Tool man
Needs a job
Posts: 4493
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posted August 19, 2008 04:09 PM
Here are two of the best ways....
(1) Take it to a machine shop that has an EDM machine. They can burn out the screw like it was never there. Tell them the screw O/D size and they will burn it to the tap size and the threads will fall right out.
(2) Take it to a TIG welder and have him build up a small series of beads till you can grab it with a vice grip and twist it out.
(3) Use an EZ-Out as said above. If that does not work...
I am a Tool Maker with access to an EDM machine if you want to ship it to me I will be glad to get it out for ya.. PM me
____________
The banks are failing..
The banks are failing...
Invest in Ammo
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bono1
Parking Attendant
Posts: 11
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posted August 19, 2008 04:52 PM
If you have excess to a stick welder just use the smallest rod and push it in the hole and hold pressure and the ground to the basket(safest thing is to disconnect battery) and just flip the welder on then off as quickly as possible. Most bolts like that will just screw out with ease if they are not bottomed out.
I have used this technique a time or two with great results.
Good luck
Sam
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obba
Expert Class
Posts: 455
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posted August 20, 2008 12:23 AM
With Warbirds idea,
I'd drill a small 2mm hole with a normal drill, then use a 4-5mm left handed drill so that it gets a grip and 'jams' - 'catches' in its reverse motion. That might be enough to 'shock' it to turn.
Humm, maybe high speed to drill the 2mm (Small drill size so no 'real' problem of tightening the bolt), then low speed for the undoing methinks....
Must say i never heard (or thought), of left hand drill bits... Have to look at some now. Good thing about forums!
Toolman: Never heard of a EDM - looked it up, and that's some serious shit! Something else i learned today....
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1badzx12r
Needs a life
Posts: 8321
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posted August 20, 2008 05:08 AM
quote:
Be real careful with cheapo ez-outers. Cause they can snap and leave you in a worse position than before.
1) Get good quality Ez-outs. Maybe borrow a couple of pieces from the local bike mechanic.
2) Use a centre puch to make sure you get DEAD centre for the drill.
3) Use a big as possible (within reason), EZ-out bit size - the thinner = more snappyer.
4) If you can heat up the surrounding area - Hairdryer maybe or blow torch on a low flame. This will expand the metal very slightly more than the bolt, as the bolt will be (I think), of harder material.
Another way is.
1) Centre punch the bolt.
2) Drill a hole 2mm smaller than the bolt and about 5mm deep.
3) Heat the surrounding area if possible.
3) Get a flat head screwdriver and 'tap' it into the new hole - how hard you tap is up to you and undo it if you can.
Another way (has worked in the past for me).
If you have good diagonal access to the top of the bolt. With a small flat head screwdriver - chisel? tap (hit), the bolt (top left quarter), diagonaly at about 10-11oclock in a downwards undo direction (if that makes sense!!!).
If it starts to move/turn, then you should have no hassle using this nick to slowly work your way around - it's just a hassle as the bolt comes 180degrees around...
Good luck.
GOOD ADVICE ...But he's not pulling a 150 ft lb tractor exhaust bolt that's seen weather for 20 years ...his bolt is a 6lb and no TQ cause heads gone ...basically you could super glue a screw to it and get it out
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1badzx12r
Needs a life
Posts: 8321
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posted August 20, 2008 05:13 AM
Edited By: 1badzx12r on 20 Aug 2008 06:17
quote:
I am a Tool Maker with access to an EDM machine if you want to ship it to me I will be glad to get it out for ya.. PM me
does this machine heats in liquid fluid to keep the aluminium cool from warp-age ...
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ninja12
Needs a job
Posts: 3310
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posted August 20, 2008 05:33 AM
Maybe someone has a extra inner basket.
They are not very expensive.
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nightmare
Pro
ACP Racing
Posts: 1797
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posted August 20, 2008 10:42 AM
Just a question for ghost man. Where are you located. If you were close to me here in Beaufort South Carolina, I would say let me do it for you! We have outstanding EZ outs in the shop used to get stripped fasteners out of the jets! I'm sure some of these guys on here would help oto if you was close enough to them! 
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2006 ZX14 Ninja "SWINE FLU"
60ft 1.23
8th Mile 5.16
ACP Racing
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burnout
Expert Class
Posts: 216
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posted August 20, 2008 11:37 AM
Same thing happened to me. Center punch, drill it and use an EZ-out as already mentioned. You'll be done in 10 min.
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1/4 8.74@159.60
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ghostman
Expert Class
Posts: 456
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posted August 20, 2008 12:17 PM
Edited By: ghostman on 20 Aug 2008 13:44
Yep, took me 10 minutes.
Took a drill bit and rapped it wound black tape around it until it could barely fit in the hole.(This kept it centered with no risk of scraping threads on the hub)
Drilled a starter hole. After that, I use the same method with the screw extractor, leaving just enough of the tip exposed to make contact with the bolt.
Once it bit, it came right out.
Thanks for the help fellas!
Now all I have to do is wait for the UPS man to show up with the new bolts.
SON OF A . . . . . . . .WHATEVER!!!!!!
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bigdtd
Needs a job
Interceptors
Posts: 4209
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posted August 20, 2008 04:32 PM
way to go
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2006 Black ZX-14,6 inches over,16/42, flies out,BMC Street Filter,Brock's Street Meg,Brock's Radial Mount Strap,PClll with Race map,Dynojet LCD w/Techmount, ZX-14 fender eliminator,Pilot Power2CTs,Speedohealer,Pazzo Levers,Cox Radiator Guard, Garmin Nuvi 265WT
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princesskiwi
Administrator
MISTRESS of SMACK
Posts: 7688
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posted August 20, 2008 04:35 PM
Teenagers were talking to you?
That doesn't sound right.
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The dose differentiates a poison and a remedy....
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