Broken trim tab bolt; help!!

[jpa1300]

I was removing the 6 mm bolts that hold the plastic trim tabs in order to space them down in an effort to reduce porpoising; well the last one broke.
There's just a little bit of the bolt showing out of the hull insert, but it's not enough to grab.
How do you guys remove these without damaging the insert threads? I'm assuming it needs to be drilled out with a reverse drill bit.
Please help, I don't want to damage the insert threads; all tricks welcome!!

j.p.

[305coco]

mine is worse than yours

sorry to hear that bro were in the same boat here i have two broken bolts on one tab and one on the other tab after that happened i wont even touch the tabs hopefully someone will chime in and help good luck.

[jpa1300]

How the heck are we going to remove these things!!?? 'Bought a couple of reverse drill bits and an easy-out; I just don't want to screw up the inserts!

[305coco]

i have no idea , i know im stuck because the person i bought my bike from locked tite the bolts i got a set of reverse bits to but i dont think its gonna work in my case they told me to heat the bolts before removing but i didnt so ima try drill it heat it up and try the reverse bit in and that

[305coco]

hopefully no more snap

[quadzilla]

Oh No...!!

You both Have a small dilemma on your hands guys..

If it were me... (been there..)

What i'd do is get myself a small gas torch.. i must emphasize small..!!

something like this:. http://static.flickr.com/211/509382172_0e8307e4be_m.jpg

Next I'd take this SMALL torch and gently heat the sheared bold,
I'd also have a medium size hammer and small sharp chisel on hand..!!
After the bolt had been heated a little, I'd then use the chisel to turn it out CAREFULLY..!!

Another alternative method is get a small nut, and MiG weld it on, thus making another bolt in effect.

YOU need to be able to weld to go down this road..

The third option is drill into it then use an easy-out type of thing..
Something like this:.http://www.hechinger.com/hardware/to...ool-11903.html
With these you need to be able to drill straight.. not so easy upside down..!!
BUT doable..!!!!

Best of luck Boys..

Gerry...

[305coco]

big dilemma

jpa 1300 has a small dilemma all three of my broken bolt are flush with the hull ima try with a torch tommorow and see how it goes thanks quadzilla.

[quadzilla]

Good Luck With It..

Another thing you might want to try is..

When you've gave it a little heat., use a centre punch chisel,

Give the bolts some heat then a medium tap with the punch,
This might help to loosen the locktite some..??

The most important thing is: Take It Easy under there..!!!

You can do it..

Gerry..

[Minx20]

Been There

Tried all the methods except welding nut on thread. Ended up doing the time consuming method of removing internal exhust and battery box and replacing them all from the inside. I now use Never-Seize on the threads and lock washers to keep then snug.

Good Luck either way.

E.S.

[porksword]

Tried all the methods except welding nut on thread. Ended up doing the time consuming method of removing internal exhust and battery box and replacing them all from the inside. I now use Never-Seize on the threads and lock washers to keep then snug.

Good Luck either way.

E.S.

I agree. I've been down that rode with ride plate bolts already. I found that if its stuck good enough to break the bolt off in the first place you are probably going to screw up the insert anyway when you try to remove it. It can be done but obviously not by me. I spent alot less time replacing the insert than I did trying to remove the bolt.

If you decide to do it just remove the battery tray and SS. The easiest way I found to remove the inserts is put the bolts half way in, heat up the green stuff on the inside with a heat gun on high (or small torch if your carefull). Then from the bottom hit the bolts just a couple times with a hammer (it dont take much) then the inserts will pop loose on the inside. It beats trying to pry them loose.

[spud]

Ditto. New inserts and antiseize. I spent about three hours trying to get the broke off part out. Got it drilled too far went through insert, threads messed up. Bought new insert. Not too big of a deal.

[injected2stroke]

First of all I am thinking those bolts are stainless steel and very hard to drill you diffinately don't want much heat there. The best way like they said is remove the old inserts and replace them with new ones. And make sure to use anti sieze or loctite 572 which is what Yamaha calls for it's a thread sealent but it's hard to find.

[spaceman]

Well i had the same problem.

I did this, open the yellow pages, find a Mobile Thread Fix service. (they specilise in drilling threads, fixing broken studs and fitting helicoils).

Within 45mins they were at my garage.

Took them 20mins to remove the snapped stainless steal bolts, redrill, tap and then fit helicoils.

Entire job cost me us$25.

.... I now learnt my lesson and invested in a us$10 blow torch.

[txgp1300r]

Tried all the methods except welding nut on thread. Ended up doing the time consuming method of removing internal exhust and battery box and replacing them all from the inside. I now use Never-Seize on the threads and lock washers to keep then snug.

Good Luck either way.

E.S.

I think this is the only way to do it...tig weld the bolt and melt the hull....not the way to do it...the bolts are work hardened(from the break) stainless steel , a cobalt drill bit will usually drill stainless but not these bolts...been there don that....the inside bracket removal method is the best way..........if there is a small tit to grab with vise grips you can use the very very small torch method. I have one bolt broken right now and its going to stay that way for a while...i installed the metal r&d tabs and they fit tight on the hull with only three bolts.

[spaceman]

well maybe the south african guys have better tools ?

Mine came out, took the tech 20mins of high speed drilling.


Your other option, is to remove the bracket on the inside and fit a new one.