Broken Kick Start Bolt

[jasonmorash1]

I looking to see what you guys have for recommendations. I bought a 93 a little while back and im rebuilding it. When i bought it the bolt that holds the kick starter in place had broken off. Also, there was no part of the bolt sticking out to put vice grips on or anything like that. It was more so in the rod. So I tried getting it out with a variety of easy-outs. Failed. On the the cheap easy outs ended up breaking off inside the hole i drilled to assist in getting the bolt out. So i tried drilling the easy out out and the drill bit broke off. I cant get any of it out now.

To sum up, in the kick start rod i have the broken bolt, a broken easy out and a broken drill bit all stuck in there lol

Im looking for the cheapest route possible.

Cheers
Jason

[Sapper]

Truthfully, Ive had that happen a few times in many years and even using a drill press, the bits just flex too much. Now I just bite the bullet and find a kickstart shaft on ebay or just order a new one. The last one was on my sons 100 and it was about $36.

[KXcam22]

Thats a tough one.  This is stretching it, but the shaft is quite large.  It may be possible to slowly drill out the whole mess to a larger size then tap the hole for a larger sized bolt.  You would need a bottoming type tap.  It doesn't even matter so much if the new hole is exactly centered since all the bolt does is hold the kickstart on.  I locktite and torque mine. The locktite holds it on and also keeps corrosion out of the threads so it won't gall on there.  Good luck. Cam.

[Friar-Tuck]

 Jason I have to give you an "A" for effort!  and an "A" for Honesty!
    Unfortunately the materials the parts that are left in the bolt hole are tough to get through, but not impossible.
 There are a few things you may consider,
   Are you in an area with machine shops.  You may make a few Phone calls and ask what it would cost for repair.
 There is a process that will actually burn out the drill bit and easy out, and then finnish the removal of the bolt.
 that may be worth persuing, or they may drill the whole mess out like Cam suggested.
   Click around the net to estimate a price for  a new or used replacement and gaskets.
      Good Luck,
   Tuck\o/
 

[bob larry]

Get an easy out that is one size bigger.   Get a diamond tip drill bit for it and try again.
A little heat on the outside of the kick shaft would help too.

Put the bike up against a wall so you can push like a bull on the shaft.

[Johnniespeed]

 Bring the kickstart shaft to a tool and die shop that has EDM or ELOX machines, they can burn right through that tap,drill and easyout, using a poco carbon electrode. It is best to find a retired guy who has connections within a shop, the retired guys usually like a challenge and dont mind wasting a half hour to conquer a challenge.
 Or you could just buy a new one for $71.19

[sandman540]

try a cobalt left handed jobber length drill bit. depending on what the root diameter of the threads are is what size bit you will use. also drill slowly with steady pressure. good luck

[ZETTNORCAL]

That sucks
 I would first try a  reverse cut drill bit and drill real slowit should turn it right out.

If that does'nt work what I do is hold a nut up to the broke off part with some plyers then Weld in the middle of the nut so that you weld the nut to the boken bolt. Then put a wrench on the nut and turn it out. The heat from welding seems to help this out too!

[jasonmorash1]

Thanks for the input guys. Im sick of fooling around with it. I think i may just take it out and see what theyll charge me at the shop. Ill decide from there what i should do.