oil drain bolt in case

[jyellard]

When tightening up the oil drain bolt, the head broke off. I must have cracked it previously, as I didn't torque it very much at all when the head snapped.

First I try to use an allen to see if there was enough of the allen hole left to get the rest of the bolt out. No luck. The I try an easy out, but the what was left of the hole wouldn't work. Now it gets ugly. I try to drill out what is left of the bolt so that my easy out will work, and the drill bit threads the rest of the bolt into the case.

Anyone have a trick I can use to retrieve this bolt without splitting the cases?

Thanks,

Josh

[gasgasman]

The cases will have to be split.
Even if your were able to fish the bolt out, you will have to screw it out while removing it.

You can try removing the clutch assembly and see if there's enough room to fish it out.

Always use a left handed drill bit when using easy outs. Most of the time, the drill bit will screw the broken bolt outwards.

Good luck.

[Cruiser]

pull the clutch side cover and you might be able to fish it out.. your does have the magnet on it right? I did this once on my 97 when I first got it.. The previous owner damaged it and when I went to swap oil the first time the head just came off..
Good luck..

[jyellard]

I have an 07' EC300, which I should have specified in the first place.

Is there a still a chance of getting it out by removing the clutch? Will I need any special tools?

[Skidad]

Here is a link to a recent discussion of a similar problem on KTM Talk. You may find this very helpful. It's on the second page of the General Dicussion section as of 3/12/09


http://ktmtalk.com/index.php?showtopic=331756

[ferguscawley]

Originally Posted by jyellard

I have an 07' EC300, which I should have specified in the first place.

Is there a still a chance of getting it out by removing the clutch? Will I need any special tools?

My money is on splitting the cases.

Download the workshop manual (manual_taller.pdf) from the www.gasgasmotos.es website. Its fairly well explained and photographed in there.


Fergus

[Cruiser]

Special tool,, luck.. and lots of it..