How to remove a broken bolt from your dirt bike.

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Sandblaster
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How to remove a broken bolt from your dirt bike.

Post by Sandblaster » Fri Oct 12, 2012 12:26 am

Ever broke a bolt off even after soaking it in penetrating oil over night?
This has to be one of the most frustrating things that can happen.
Check this out:

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As you can see this bolt broke off with just enough left to get a good grip on.
Here is some different ways that you can remove a broken bolt depending on how bad it is broken.
The first thing I do is apply heat directly to the bolt.

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Then, grab the bolt with some vice grips while it is still hot and try to unscrew the bolt.

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This bolt is really stuck.
So, I took a nut that is larger then the bolt diameter.
The reason I use a larger nut is so that I can get some good penetration as I am a very poor welder :(

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Place the nut over the broken bolt.

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Weld the nut to the bolt.
Pay close attention so that you get good penetration.

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As bad of a welder as I am, this weld turned out very good (For me).

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Next, put a wrench on the bolt and attempt to unscrew it.

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As I tried to unscrew the bolt I snapped the shaft right off.
So, I took a grinder and flattened the bolt off to get a good clean surface.
Sometimes the bolt will break deeper into the threaded area and then your stuck working with what you have.

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Then I take a center punch and put a nice little dimple for the drill bit to get started in.
Try to get the dimple as close to the center as possible.

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As you can see, I was a little off with the center punch.
It was still close enough to drill out the center of the bolt.

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Then. I apply heat again.

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Insert the Easy Out (This is my least favorite easy out. My good one was broke)/
Then try to back the bolt out.

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The broken bolt came out and I couldn't be happier.
The threads were saved.
I did run a tap to the bottom just to be sure that there was no messed up threads.

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All done.
If you have any questions or suggestions, feel free to post or email.
SB
If bikes are for kids I'll never grow up.

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