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Old 06-21-2012, 09:59 PM   #1
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broken primary clutch bolt

2002 zr 600. clutch blew apart, found that previous owner must have over torqued the primary bolt becasue it is broken off inside the thread of the crank. cut the clutch off, but I still need to get the broken bolt out of the hole. it is broken off about a 1/4 inside. I have a hole tap driled in the bolt, ready to use an "easy out" tool to spin the broken piece out.

the current issue is how do i hold the crank shaft from spinning while turning the easy out wrench? I need to keep the shaft from moving but without a clutch on it... how can I hold the crank in place without damaging the cone that the clutch slides onto?

hope this makes sense.
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Old 06-21-2012, 10:18 PM   #2
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If the jugs are still on it I would take some nylon type rope and push it thru the spark plug hole. Be sure the piston is in the up stroke and passed the ports. If you have enough rope in the cylinder it will lock the crankshaft in place. Some will ague this is a bad idea, but it should not take ton of torque to back the bolt out
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Old 06-22-2012, 06:09 AM   #3
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Another option would be to take the pull start off and hold the starter pulley
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Old 06-22-2012, 02:10 PM   #4
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 Quote: Originally Posted by Papaspeck View Post
If the jugs are still on it I would take some nylon type rope and push it thru the spark plug hole. Be sure the piston is in the up stroke and passed the ports. If you have enough rope in the cylinder it will lock the crankshaft in place.



Have you been spraying the Broken bolt with PB Blaster? If not I would for several days before attempting anything, you defiantly do not want to snap an easy out off in there.
What we have done in the past is drill out as much of the bolt as possible without hitting the threads, keep spaying blaster the whole time, most times you can use a pick and turn the broken piece out.
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Old 06-22-2012, 04:00 PM   #5
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I would soak the crap out of it with some good penetrating oil, and then pull the recoil off and use the starter cup to hold the motor from turning.
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Old 06-22-2012, 04:48 PM   #6
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I have used the rope trick many times. Works great.

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Old 06-23-2012, 12:57 AM   #7
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 Quote: Originally Posted by dadszr View Post



Have you been spraying the Broken bolt with PB Blaster? If not I would for several days before attempting anything, you defiantly do not want to snap an easy out off in there.
What we have done in the past is drill out as much of the bolt as possible without hitting the threads, keep spaying blaster the whole time, most times you can use a pick and turn the broken piece out.
this works, as long as your anal on making sure the drill bit is centered and straight.

by hand, on the sled, probably not a good idea.

on the bench, maybe.

chucked up in a press, always.
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Old 06-27-2012, 07:25 PM   #8
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rope trick sounds like a good idea assuming the broken piece spins out with little torque. This one seems to be in there tight.. I will try holding the startor cup first.

The problem I have is thanks to me being an idiot and not paying attention, there is a drill bit broke off inside my pilot hole through the bolt . The hole is deep enough that I can grip the bolt with an easy out but I cant drill the hole any bigger...



I will try it tomorrow.
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Old 06-27-2012, 08:38 PM   #9
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my local fastenal has drill bits, that will drill out other drill bits, though not easy outs.
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Old 06-28-2012, 05:59 AM   #10
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I went through this kind of thing on a 650 Polairs Pro Stock I am building and once I broke off the easy out (a Snap On I might add) was when the trouble really started. It took me about 10 good drill bits to even get part of the Easy out part way drilled out then I gave up.

I took the engine to a local Speed/Machine shop showed them what i had and they said thank god you didn't destroy the threads but even if you did no big deal just more money.

80 dollars later..... problem fixed....That was the best 80 dollars i ever spent on an engine.
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