Broke bolt extractor - what to do?

NuggyBuggy said:
Was able to get my bike up with the front wheel raised pretty high, giving pretty good access to the bottom of the fork leg. Used my Mastercraft Maximum cobalt drills, but they weren’t cutting very well, so switched to Milwaukee Cobalt drills which were much better.

Tried to drill out bottom, I believe I drilled through most of the threaded portion. I tried to center punch a hole but I was still off center. Went through as many sizes of drills as I could, but not as many as ideal because I was off center. Didn’t go the route of using an extractor yet as the only ones I have are left handed, and using that from the bottom would tighten the screw (unless I grind off the head or cut the screw in half)

I hammered in a Torx bit into the head of the screw. I was surprised how well it grips. Tried to turn it with my 12V impact driver but still not moving. I went through several rounds of heat (until the farthest part of the fork leg was very hot to the touch), penetrating oil, and impact driver. Still not moving. Considering using a heavier duty impact wrench but that requires a 3/8” socket drive bit.

I’m going to take a shot at this for a few more weekends. Entertaining cutting the screw and removing the forks, but that looks like maybe more work than I am interested in.

Getting to the point where I’m considering selling the bike or trading it in. I love this bike but my wife is starting to convince me I should get a smaller, lighter, easier to manage bike, especially with our limited space.
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Do not hit it with an impact gun, if anything get a rachet on it.

Waht area are you in? maybe i can give you a hand
 
MCT said:
And my flat blade bits are not the usual ones that are angled towards the tip but the ones that are parallel.

Sort of like these but the ones I have the tip is even more parallel. You get a better bite on the whole surface of the screw head and not just the top edges of it.

View attachment 75416
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In my case the jet was just too torqued from the factory. I have proper carb service drivers, the jet simply split.

Not the first time I’ve dealt with stuck or broken pilots… but it was the first time I had to deal with a factory problem on a new carb.

Bu the way, you couldn’t use the bit you show on most pilots or air screws - wrong tool.
 
I didn't read all the posts.

When tightening this type of pinch bolt assembly I note they have to be done in series back and forth. You tighten one to spec and it effectively lessens the tightness on the other bolt, so you go back and forth until they are both tightened the same.

Have you considered over tightening the bolt on the left by maybe 10% - 15% (maybe more...........??) to see if this effectively reduces pressure on the stripped bolt on the right.
 
ReSTored said:
Have you considered over tightening the bolt on the left by maybe 10% - 15% (maybe more...........??) to see if this effectively reduces pressure on the stripped bolt on the right.
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I have, while trying to avoid stripping the threads on the other bolt. Didn’t make a difference yet. Someone else made a suggestion to use a clamp to accomplish the same thing. That’s something I can try next weekend.
 
timtune said:
Wives sometimes know stuff. I had a KZ650 disembowled in the garage when the Squeeze suggested getting a new bike. I did not need to be told twice.
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i hear you. Besides the problem of selling this one in its current state is the problem that there is no other bike that I really pine for. Not that ticks off the box of not being another project for me, anyways. Excepting the ones I know aren’t really a good fit - like a Panigale V2.
 
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