Clutch problem - snapped screw. Bugger.

[D O G]

Okay, decided to do the plates on the clutch, and combine it with an oil change etc.

Got everything apart easy enough - cover off to reveal the clutch assembly.

I was greeted by only four screws holding the springs in, and four springs instead of five. Arse. The fifth screw, at some point in th past had been snapped, and left half of itself in the clutch boss post. Most annoying.

Explains why it was slipping. Damn shame I have already bought the plates

Now my problem is getting it fixed. I have never attempted extracting such a screw - it is about 3mm down from the top of the post, perhaps 3-4mm in diameter, and the snapped surface is not smooth. My GF fancies giving it a go, I do not.

I don't have a tap & die set, although I do have a set of drill bits and hand drill which could probably help.

I do, however, think that it would be best to take the clutch boss off the bike to perform any operation, which then made me think the whole piece would be much less painful if I either get a 'new' boss, or take it to someone to have it done. What do you guys think?

[andi]

Is the hole blind? With the offending piece removed, would it be possible to access the broken bolt end from behind? This would offer a flatish face for the drill

A machine shop will almost certainly be able to fix but I would have a go myself first. Saying that I have the luxury of access to a machine shop if it goes pear shaped so maybe i am biased
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Before: Suzuki GT 185. Honda Superdream 250. Yamaha RD350LC. Suziki RG250. Yamaha FZS600. Honda CBR600F3
Now: Honda Fireblade 929

[Kickstart]

Hi

Personally, given the speed it spins at and the potential mess should that bolt come undone with the engine running I would take the basket off and drill it out very carefully. Not with a hand held drill.

Basket comes off fairly easily.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Ichy]

I agree with KS but would definitely consider taking it to an engineering place to drill out and clean up. I have a set of left hand drills that are perfect for this kind of work, assuming your drill is reversible. This place sells them for £5 a set. The are used but have been reground and are high quality.

https://www.tracytools.com/variousclearance.htm
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[D O G]

Yeah, I think it will be best if I take it somewhere and have it sorted, since it will be a quick, easy job for somewhere with the correct tools and know- how.

I suck doing things like this - fine control is not my strong point. Likely that it will cost me a lot more (and a lot more time) by trying to do it myself, and very likely that I will destroy the part.

[D O G]

Well I had a look at it this morning to see what the crack really was. Poked it with a screwdriver, and it turned freely! 30 seconds of poking with a screwdriver and it was out.


So pleased.

Unfortunately the local breakers did not have a set of springs and bolt, so have to wait until Tuesday when the dealer can get them in.

Still, much better than having to deal with a PITA from a stuck bolt.

I really cannot believe whoever did that just left it. Unbelievable.

[Pete.]

The bolts are just normal M6 bolts - nothing special about them. The spring would need to be somewhere close I guess.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[stinkwheel]

A clutch bolt would almost certainly EZ-out ok. There will be next to no pressure on the threads and certainly no corrosion. It'll have been broken by overtightening it going in.

People snap extractors because they try to use them to extract a seized-in stub. This won't work, it's seized. Snap a bolt putting it in and extractors are very useful. I've used them to great sucess for both rocker cover bolts and sparkplug threads for example.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Gazdaman]

Always buy new springs! Don't go for breakers springs!

You'll see why when you compare the length of used springs to new ones.

Gaz