How screwed am I? Oil galley bolt snapped off when tightening.
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Thread: How screwed am I? Oil galley bolt snapped off when tightening.

  1. #1
    Junior Member talon125's Avatar
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    How screwed am I? Oil galley bolt snapped off when tightening.

    As you can see from this image, the head snapped off that bolt. How screwed am I? Is this going to be a super expensive fix? Can I ride the bike to my shop or will I need to get it towed?
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  2. #2
    Senior Member SHAG's Avatar
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    Back the threads out with a knife and get a replacement at a hardware store. Get a washer also if you lost the original.
    Go like hell, You'll get there quicker!

    2005 BMWR12GS Rock Red 106k miles
    2013 TW200 - 8k- miles
    2018 X-MAX - 6k- miles

  3. #3
    Junior Member talon125's Avatar
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    Wow. That's it? lol

    Any chance you know the exact type of replacement I should be looking for?

    edit: it's pretty deep in there. Not sure how I can get it out with a knife. Any suggestions?
    Here's a better image.7Qe5Pvz.jpg
    Last edited by talon125; 10-26-2018 at 08:44 PM.

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  5. #4
    Senior Member Badgerflorida's Avatar
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    If it’s not leaking bad you can ride it to the shop but keep an eye on it for a gusher. I believe you need part #3 from this photo. If it were me, I would try to notch it enough to get a standard screwdriver on it and back it out. Sorry I can’t give you the specs on the screw. Maybe someone has them. If you can get the rest out, take both pieces to the the hardware store and they can help you figure out a suitable replacement. Cheers and good luck.
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  6. #5
    Senior Member silverwing's Avatar
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    Take a small, sharp pointed object, like a scratch awl and back the broken screw out in a counterclockwise rotation. Don't ride it anywhere until it is fixed properly.
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  7. #6
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by talon125 View Post
    As you can see from this image, the head snapped off that bolt. How screwed am I? Is this going to be a super expensive fix? Can I ride the bike to my shop or will I need to get it towed?
    Here are my suggestions:

    -With the engine running, does oil leak out (i.e., gush, spray, ooze or nothing)? If if doesn't leak significantly, you should be okay to ride it as long as you keep an eye on it and your oil level.

    -If it is only leaking a tiny bit, you could try to clean the threads well and seal the opening with some high-temperature silicone sealant as a temporary fix.

    -I've heard that you can get reverse-twist drill bits that can be used to remove broken bolts like this one. A standard twist bit may just drive it in further/tighter.

    -If you are able to get a small hole started, clean it out well, and try epoxy-ing the long end of a small allen wrench onto the broken end of the bolt. After it cures see if you can gently unscrew the broken piece.

    -If you have access to a gas MIG welder, you could see if you could tack weld the long end of a small allen wrench onto the broken end of the bolt.

    That's all I've got.

  8. #7
    Senior Member kj7687's Avatar
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    Get a flat-blade screwdriver that's quite narrow/knife-like on the end, that is just wide enough to cross the diameter of the hole. Then get a hammer and tap away at it (making sure the blade stays on the same spot of the broken bolt-head) until a chiseled groove starts to farm. Get enough of a groove and you have yourself a fancy flat-head screw that can be removed (maybe) lol. Depending on what the break looks like, you may want to flatten out the "head" surface of the broken bolt first. It's worked for me at least a couple of times in the past. Good luck.
    admiral likes this.
    KJ, just KJ, ok.


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    Senior Member Gastone165's Avatar
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    Plan a long ride. Invest in expensive non-refundable reservations. Don’t bring any tools, spare oil, spare parts or a cell phone.
    It’s sure to fall out somewhere during the trip.
    1972 Yamaha DT 175, 1974 Kawasaki 125, 1976 Suzuki TM 250, 1979 Yamaha 750, 1977 Husquvarna 360, 1979 Husquvarna 250, (2) 1980 Suzuki RM 400’s, 1971 Husquvarna 400, 1983 Honda V65 Magna, 1987 Suzuki 230 Quad, 1987 TW200, 1990 TW200, 1996 Honda XR 650, 1998 Yamaha 300 King Quad, 2000 Harley Davidson Heritage, 2006 Kawasaki KLX 250s, 2007 Arctic Cat 650 Quad, 2010 Polaris Sportsman 850 Quad, 2006 Yamaha Grizzly 660 Quad, 2002 TW200, 1995 TW200, 2008 TW200, 2016 TW200.

  10. #9
    Senior Member GaryL's Avatar
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    First you need a very sharp pointed punch so you can make a mark in the middle of the broken stud for a drill bit to drill into. Start with a new and very small drill bit. Increase the size of the hole with larger drill bits. Get a good quality EZ out drill bit that fits the hole you drilled into it. EZ outs are very sharp reverse bits that lock into the hole in the stud and should walk the stud backwards and out. Be very careful to not screw up the threads in the head while drilling. Once you get the broken stud out buy the exact replacement bolt as shown above and do not cinch it down so tight that it brakes.

    GaryL
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  11. #10
    Senior Member Trail Woman's Avatar
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    oops...double post?
    Last edited by Trail Woman; 10-27-2018 at 08:56 AM.

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