Results 1 to 8 of 8
  1. #1

    Help! valve cover screw broken!

    Im freaking out here, I broke one of the valve cover screws on my 4tec, I bought one of this extractor kits (peace of crap, dont buy it)

    While I was drilling a hole on the screw the drill bit broke, it was a pain to get it out, but I managed and I got the extractor in but when I was turning it it also broke! damn, and its fused to the screw, now I cant get it out and I dont know what to do!! please help!! What do you do in a case like this? new head? machining? can I use it with one screw missing(plugging the hole)? Im so lost

    I dont know if I should take it in to the dealer, I have had VERY bad experiences with how the work here in Cancun...

  2. #2
    You can probably drill it out and re-tap it. Make sure you drill the broken bolt in the centre and slowly go with a larger bit each time.
    Then re-tap it May have to use a slightly large bolt.

    Be careful with the iron filings.

    Much cheaper than a dealer.

  3. #3
    Stainless is very difficult to drill. Have to start small an work your way up. May be easier just to grind the head off with a dremel. Once the valve cover is off, the stud will be pretty easy to remove.

  4. #4
    R88ory RXP's Avatar
    Join Date
    Feb 2008
    Kent, England
    Sadly, in my opinion you need to remove the head and get it to a machine shop and let them mill the old screw and extractor out. I had one thread pull on my head so was able to drill it and fit a time-sert thread repair insert. but trying to drill a bolt out of a head with a pistol drill is asking for trouble especially now it has a very hard extractor stuck in the middle, trying to drill down the centre will be difficult.

    The machine shop would be able to cut out the broken bolt and fit a insert to replace the thread.


  5. #5
    I managed to get the screw out!! I wouldnt use the screw extractors ever again, it just complicated everything extracting the extractor out of the broken screw I had to extract. Would have saved me allot of trouble just using the inverted drill bits.

    But my jet is out and running like a champ, Im so glad, Thanks to all that offered help and advise, really appreciate it.

  6. #6

    Join Date
    Mar 2006
    next time just bring your problem to a good local welder. He will just put a small bit of weld onto the end and use a set of vise grips to turn it out. Usually 5 minutes or less from start to finish. The 1st time I seen this done I could not believe the results.

  7. +1 by:

  8. #7
    This is how I run a jetski shop in the desert nmpeter's Avatar
    Join Date
    May 2008
    Elephant Butte New Mexico
    the welder next door to my shop as done some pretty amazing stuff

    if hair was made of metal..he could weld it.....

    better to remember what you are doing and step back BEFORE you have this kind of problem.

    Don't use anything less then top shelf tools when working on stuff like that.

  9. #8
    Chupacobra's Avatar
    Join Date
    Jun 2012
    Orlando, FL
    Helicoil it. Use a colbolt brill. Slow speed, good consistant pressure, lube.

    Or... just leave it as is probably won't leak

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. valve cover screw seals
    By addicted in forum 4-Tec Performance
    Replies: 3
    Last Post: 11-04-2014, 11:37 PM
  2. oil under/around valve cover screws
    By WS6 GreeN in forum 4-Tec Performance
    Replies: 1
    Last Post: 10-21-2012, 06:29 PM
  3. Rotary valve cover alignment HELP!!!!!
    By ryanwoodard in forum 2-Stroke Performance
    Replies: 14
    Last Post: 09-20-2012, 10:03 PM
  4. HELP Valve cover gasket
    By beachbum0286 in forum 4-Tec Performance
    Replies: 6
    Last Post: 05-10-2008, 12:36 PM
  5. Air suction block offs (aka: Valve Cover block offs)
    By earthshaker in forum Kawasaki PWC Performance (4-stroke)
    Replies: 0
    Last Post: 06-19-2007, 08:16 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts