Bonneville America Forums Forums Technical Forums General Tech Help, Broken Bolt

I am so frustrated. I was trying to remove my rear pillion seat last night and for some reason, my "tool Free" bolt was stuck tight. It would not budge, so I went and got my pliers to try and get the thing off and after a couple of turns, I thought I was home free. Not the case, half of the bolt broke off and is now stuck in hole. I have no idea how this happened in the first place since it was hand tightened the last time it was put in, but now I have no idea how to get the rest of the bolt out. Does anybody have any idea

Two methods I know of, having sheered many a bolt in my time.

If some of the bolt is above the hole, use a stud remover. Basically a large nut, with a hole through it and a cam which tightens on the stud as you turn it.

If the top of the bolt is flush with the hole, you need an easy out. With this method, you drill a hole into the remains of the bolt. you tap the whole with a reversed thread (tap will be in the kit) you then screw the provided stud into the hole and as you keep turning it, it pulls out the stud.

Other than that, there is the cheaper method of just drilling it out, re-tapping it and then using a slightly larger bolt.

I have always had good luck with the Craftsman bolt and screw extractors, the kind you chuck in a drill and reverse out. I have only needed it once on my America, to get the foot control bar off.

Spray some WD 40 or something and let it soak for a bit.
If you dont have an EZ out you can use a regular drill bit and push it through the hole by drilling into it. Just make sure you use the smaller drill bit than the hole. Slow and careful.

I'd just drill it it out.go stright through with a number 7 drill then retap the whole unc 1/4-20 should be pretty easy to do.
(just dont break the tap).

I am asuming her that you are talking about the bolt that holds down the back of the p-pad.

Feel under the fender to see if there is any poking thru first. Might be able to grab the tip and thread it thru. Soak with WD40 whichever you choose to held

Try to find a left-hand drill bit. Drills in reverse. If its the same bolt I have, its aluminum and should come out easily. Usually, once a bolt head is broken off, the threaded part isn't tight anymore.

Update:
I got an easy out bit, and got it out. It was really wedged in there, and although it didn't come out with the easy out bit, once I had driven it all the way through, there wasn't a lot of the bolt left so I was able to just punch it out with a screw driver. Not very surgical, but it worked and the threads are still intact. I will not be replacing the "hands free" pillion seat bolt, too soft! Thanks for all of the help, as usual, you guys always come through!