Snapped screw in triple tree - HELP!

[mindactivated]

So, on my Honda CX500D (1980), the bottom right screw is broken almost flat with the little opening on the triple tree, on the inside.

How do I get this sucker out? PB Blaster... heat (what kind? Fire??)... a drill... What kind of drill bits? I'm a super noob when it comes to this but I'm still trying to learn and do it on my own. So far I've tried soaking it with PB Blaster, and then next step I'm at a loss.

Would this be the correct step process?

1) Soak with penetrating fluid (e.g. PB Blaster)
2) use a punch? (like this?)
3) Either try to unscrew it with a flat head, or use a drill bit? What size drill? Fuck I need a drill...
4) Use an extractor bit? I have a couple but frankly I've never used them before.
5) ???
6) Profit!

Maybe I answered my own question but if someone could chime in on do's and don'ts then that'd be great. The last thing I want to do is get a drill bit stuck in there. Oh and in case anyone's wondering if I'm completely useless for asking these questions, no I can take some decent pics and I can also fix my own computer.

 

[Mr.E]

Step 1: be very patient! This task can take time and be very frustrating.

Step 2: start small with the drill bit. Its even betting if you have a center drill bit to start with. (Stubby bit with small nose for starting holes.

Is your tree drilled all the way thru so you can see the end of the bolt? Or a blind hole (ie: can only see the broken side, not the bottom) if you can see the bottom of the bolt, there is a small chance you can use a small drill bit to "unscrew" it by slowing drilling on the end and causing the broken bolt to back out the way it came.

If not, try a screw extractor, and keep a steady hand! I prefer to use an "ez out" style that is one reverse drill bit to drill a pilot hole, paired with an extractor to mat h the hole for best fit. Use a tap handle on the extractor if possible, or an adjustable wrench in a pinch. I spend a good portion of my work days pulling broke bolts from things like this. Do you know what size bolt it is? Ez out kits are available at most any hardware store, and I don't really like the ones that are drill and extractor in one bit. They are made to be used in a power drill and they can sometimes make a mess with one little slip. Be patient, you can do it. If not, a mechanic or machinist would do it for a small fee.

Also a good idea to run a tap thru the hole once the bolt is out, just to clean up any birds.

 

[mindactivated]

Step 1: be very patient! This task can take time and be very frustrating.

Step 2: start small with the drill bit. Its even betting if you have a center drill bit to start with. (Stubby bit with small nose for starting holes.

Is your tree drilled all the way thru so you can see the end of the bolt? Or a blind hole (ie: can only see the broken side, not the bottom) if you can see the bottom of the bolt, there is a small chance you can use a small drill bit to "unscrew" it by slowing drilling on the end and causing the broken bolt to back out the way it came.

If not, try a screw extractor, and keep a steady hand! I prefer to use an "ez out" style that is one reverse drill bit to drill a pilot hole, paired with an extractor to mat h the hole for best fit. Use a tap handle on the extractor if possible, or an adjustable wrench in a pinch. I spend a good portion of my work days pulling broke bolts from things like this. Do you know what size bolt it is? Ez out kits are available at most any hardware store, and I don't really like the ones that are drill and extractor in one bit. They are made to be used in a power drill and they can sometimes make a mess with one little slip. Be patient, you can do it. If not, a mechanic or machinist would do it for a small fee.

Also a good idea to run a tap thru the hole once the bolt is out, just to clean up any birds.

It's sadly one way. This thing is full of surprises. I just noticed the screws are ever so slightly different (one was threaded all the way, the other was not). The long screw is the one for the other side and is intact. It is a... size 12 metric I believe. Here are pics: click on a picture for the link to the original size, and for additional notes

The Triple Tree


Up close (kinda dark)


Screw comparison & how much is snapped off

 

[Mr.E]

Ah I see now. Previous owner used a bolt that was too short. The top bolt has that nice shoulder for strength before getting to the necessary thread area. It happens where I work all th time.

Well you've got it lubed up in penetrant oil, so you could try a very small prick punch and hammer to persuade it to turn, but be careful to not damage any exposed threads. If it doesn't yeild immedietly, then go for the drill and ez outs. Use one that is just about half the diameter of the bolt if you can. Cause if it strips out you can use the next biggest one. A 12 mm bolt should be able to accept a decent amount of power to break it free. You can try heating it up a bit, but don't go crazy and get it red hot or anything (yep, I've seen it done) I generally don't condone heating things that don't need heated but some wont hurt it. And when its out and you are ready to re install bolts, use some silver anti-seize on the threads. Saves headaches later!

 

[mindactivated]

This is my first bike, and there are many very small surprises I still manage to find. Nothing life threatening (well... not anymore), but still. It's great to learn on - wrenching & riding.

A few quick questions... What is an EZ-Out? I can't seem to find what these look like online. Also, what could I heat it with? I don't have a torch or anything, could you recommend one? Thanks Mr.E!

 

[Mr.E]

An ez out is more of a shop term I guess. Look at these
http://www.thetoolwarehouse.net/p-1828-irwin-industrial-11119.aspx

These are what I use at work. Notice each extractor is paired with a drill bit. Also, if a center drill is available, they make the task a tick easier. Just use it first for a small pilot hole, then the maint drill bit, then the extractor. This is a center drill:

http://littlemachineshop.com/products/product_view.php?ProductID=1230&category=

As for a torch, any home improvement store sells a propane torch that will work. Any handheld size that takes the disposable cylinders will do. I know walmart has them, usually around the 15 dollar amount. The ones you light with a match or lighter are way cheaper than the quick fire ones, and they last a lot longer too. I've had one for over 8 years now, and used up 2 quick fires in the same time period. But the company buys them... so we use em!

 

[mindactivated]

Mr.E, and also my other friends who helped (RpBet, etc) - THANK YOU.

Got that motherfucker out!

My steps:
1) PB Blaster, let soak for a few days while I locate other tools
2) PB Blaster again, drilled into the bolt a bit of a groove, not very big.
3) drilled out with extractor bit, a bit more slowly.

I was a bit sloppy in my work but the job was done. Once again, THANK YOU.