Valve cover bolt snapped

First off the good news. The PO took care of the bike. 16,000 miles on it and it appears that the valve cover gasket isn't the original AND the valves were all in spec. Now the bad. As I went to tighten the last bolt (the bolt closest to #4 exhaust) all it did was spin. I was able to pull it out and it appears to have snapped where the threads meet the unthreaded portion of the bolt. My stomach sank and I packed it in for the day. Questions: Should I panic? Has this happened to anyone? How do I remedy the problem?

 

i did that, bought a used set of cam caps on ebay

 

Foolber; huh? cam caps have nothing to do with the valve cover. I'm confused... unless you're talking about replacing the bolt with another bolt from a used set of cam caps (which is not similar anyhow)

Ned6x4; the bolt itself snapped after the bolt was fully tightened? The valve cover does not need to be that tight. Use less than 10 ft.lbs. to fasten the valve cover next time. You're lucky you didn't crack the engine head (don't ask me how I know that...) being that the location is on a corner of the engine head.

seems like a simple solution in my eyes would be to remove the snapped portion of the bolt with an easy-out. I'm sure others will chime in

 

Should be able to extract it pretty easily with an easy out if you take the valve cover back off. Especially if you just recently had that bolt out ( meaning its not seized in there). Chacal has replacement bolts along with the donuts if you didn't replace those while you had the valve cover off. Just curious... you are using a torque wrench to tighten those down, aren't you? Those bolts have stops on them so they only go in so far, which is why its recommended to replace the donuts. The donuts are what supply the force necessary to hold the valve cover down tight... not the bolts.

 

Collect yourself.
Don't rush getting-out the remnant until you have your sheet together.

The Number-1 Rule to abide by, right now, is: "Don't make your Bad situation Worse".

The Remnant can be easily Drilled. It's SOFT Steel.
Getting to it, ... with a sharp Drill Bit, is another story.

 

Sorry, I wasn't clear. It snapped while loosening the bolts. I didn't realize it until I was putting the cover back on! I feel like Will Ferrell in Old School slamming the chair against the lockers screaming "We can't freak out! We gotta keep our composure." In all reality, I'm surprisingly calm. Just that sinking feeling at first. Then I turned to the forum. Now I'm devising plans in my simple brain and cross-checking them with advice here. Won't be able to get to it until Tuesday. I figure that gives me time to collect advice, think it out and execute a rational, educated plan. Thanks guys!

 

Since you won't get to it til Tuesday that gives you time to give the stuck half of the bolt several soakings with kroil to help free it. Is there any portion of the bolt sticking out of the head that you could grab onto with some vise grips after you soak it?

 

The broken stub should easily turn out; there's no "load" on it. Any tightening torque depended on the stop collar which is now gone so the stub should be free-spinning at this point.

 

Got it! Thanks, guys, for talking me off the ledge. After I caught my breath, I was able to drill it out. The PO over tightened the bolts way too much. I'm usually not afraid of retrieving lost bolts/screws but this one being in the engine block scared the bejeezus out of me. Thanks again for the suggestions and support. You guys are great. Till next time....

 

Hazeltucky, eh? Used to live there myself and I drive right through Warren and Centerline on my way to/from Capac/downtown Motown every day.

Holler if you get in a serious bind that could use another set of eyes.

 

Torque Wrenches. Never enter the garage without one. ^_^

 

This is your neighbor, across the Detroit River, in Windsor.......I hope that our paths will cross some day, would love to share a pot of coffee with you. You are like an encyclopedia on two feet

Ron

 

Once again, I appreciate it! I actually see a 550 like mine riding around 10 Mile and Mound every now and again around 4pm. I've seen a few others in the area and it gets me geeked and inspired to finish this project THE RIGHT WAY....and remind me never to complain about my drive to and from New Baltimore during the fall to coach! CAPAC? That's a friggin hike