Help I broke a bolt.

[speedlimit85]

I over tightened the bolt under the carburetors that is for the oil pump with the metal tube. I broke the head off.

Please help. I need to get the rest of the bolt out!

[bikerphil]

That bolt is hollow down the center, move the tube out of the way and either try grabbing it with a pliers or, if it is below the surface, try a flat blade screwdriver to twist it out.

[speedlimit85]

Alright. Thank you. I will look at it in daylight.

[bikerphil]

You probably will have to loosen the bolt at the other end of the metal tube at the cyl. head to move it out of the way.

[DiverRay]

The bottom bolt is different than the top bolt, IIRC. They are "Banjo Bolts", but I think the bottom bolt has shorter threads than the top, and most "standard" bolts of that type. Do heat the copper rings on both side of the bolt with a propane torch until red, then dunk in oil or water to "anneal" it. this softens the copper so it will seal again.

[Schming]

That bolt is hollow down the center, move the tube out of the way and either try grabbing it with a pliers or, if it is below the surface, try a flat blade screwdriver to twist it out.

There are tapered, square extractors that come in various sizes that will work well if the remainder of the banjo bolt is too stuck for the flat blade screwdriver

The bottom bolt is different than the top bolt, IIRC. They are "Banjo Bolts", but I think the bottom bolt has shorter threads than the top, and most "standard" bolts of that type. Do heat the copper rings on both side of the bolt with a propane torch until red, then dunk in oil or water to "anneal" it. this softens the copper so it will seal again.

Make sure the copper washers are off the bike before annealing

[speedlimit85]

I got the rest of the bolt out. Thank you.

[skids]

If this happened because you over-torqued it, lesson learned!

[Bonz]

Is there a torque spec for that bolt in the service manual?

I would think he’d have been careful, maybe the bolt had a defect? To torque that much to break a bolt would be really over doing it.

[bikerphil]

Oil delivery pipe bolts are 14.5 ft/lb.

[Bonz]

Good spec finding, thanks for that!

[speedlimit85]

I overtightened it while the bike was hot. I will not do that again.

[Bonz]

Thumbs up on that. I had the cam cap bolts on my ZRX 1200 stretch when I put in new cams. Discovered it when I had everything put back together was one tooth off. Had to take it apart. The bolts when I took them out felt like they yielded as they broke free.

Sure enough, there was a waist that developed where they had stretched.

I read my torque wrench wrong while adjusting it and instead of 9 foot pounds, I had done about 13 or 14. Doesn’t seem like much in conversation, but it’s 50% more. Ordered some new bolts and was very observant and diligent putting it back together.

It can sure happen to anybody.

[speedlimit85]

I replaced the bolt and used new copper washers. There is still some oil seeping out. Maybe I hurt the metal where the washers seal? Can I sand or file the area? I should be able to fix this without a shop.

[DiverRay]

200 grit or finer sand paper. do a circle motion around the bolt hole so the sanding marks go around the bolt hole, like a target. should be all you need to do.