more frozen bolts

I tried to change the fork oil. In order to do so, I had to loose the handle bar assembly, to get it out of the way.

While trying to do that I broke both tops of the bolts that hold the headlight and speed/tach to the handlebar assembly. Very smooth.

Don't know what to do. Tried the sears drill-out method on one bolt and it just stripped itself.

 

Does any stick out? I would think some would since it holds the speedo assembly. If so you can try grabbing it with vice grips.

If the easy out won't budge it you can try heat or penetrating oil to loosen it. Your other options are to drill it out and retap or drill it and helicoil.

Best thing may be to take it to a local machine shop and let a pro get it out.

A pic may help spur some ideas. Anyway those are the options I can think of, hard to say which is best.

 

Aren't those thru-bolts like on the 550's? I gotta look at a parts diagram...

 

Simple bolt that goes through (IIRC) the bracket, a rubber bushing, a steel bushing, another rubber bushing, into the headlight bucket bracket.

 

ANOTHER ALTERNATIVE might be to have the machine shop drill-thead new
holes next to the originals - and just move your brackets over a bit on the light assmby... IF THATS POSSIBLE.. NOT SURE.. but its a thought..

 

One of my bolts broke off like this as well this evening... Oak450 did you have any luck with this?

 

8O if you can see a bit of the bolt try welding a washer to the broken bit with a mig welder then use some visegrips but soak with some wd40 or what ever. :wink:

 

It sounds like the headlight bracket bolts. Should have only been the handlebar clamp bolts.

 

Had the same thing happen to me. Saved myself the agony and grief and took it to the shop. $35 to drill it out and rethread the hole.

 

My neighbor and former Seca 400 owner managed to help me drill out and re-thread the bolt... gotta be careful with those old beasts don't we? needless to say i purchased a bottle of anti-seize compound Thanks for the advice guys...

 

Glad you got it fixed.
I got tired of broken bolts, started using Aero Kroilon everything before trying to take it loose.

KanoLabs still has a Google Special on Aero Kroil.
2 - 13oz cans delivered to your door for $12.00.