I think I'm screwed here. Help?

Ardenb64
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Ardenb64
Edited Date/Time 4/8/2016 8:54am
So I'm torquing down my shifter bolt, and snap! The whole thing comes off in the spindle. After some explitives, I get my tap out and drill bit. I get nearly finished for the job, and THE DRILL BIT BREAKS OFF IN THE SPINDLE.

This bike (2016 Kim 450sxf) has 4 hours on it. I'm freaking out that I'll have to tear the whole bottom end apart to replace this thing. Please help?

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RMRider1
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RMRider1 4/5/2016 7:28pm
4/5/2016 7:28pm
Buy a grabit kit and proceed to back it out. Can purchase at most hardware stores I believe...
Ardenb64
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Ardenb64 4/5/2016 7:32pm
4/5/2016 7:32pm
Thanks @RMRider1.

I got the drill bit out. I had needle noses small enough to jar it loose, then I got a magnet to pull the piece out. I just need to get a different tap tomorrow I suppose.

I'll still take any pointers I can get. I've thankfully not had to do this very often.
Ardenb64
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Ardenb64 4/5/2016 7:45pm
4/5/2016 7:45pm
Thanks @RMRider1.

I got the drill bit out. I had needle noses small enough to jar it loose, then I got a magnet to pull the piece out. I just need to get a different tap tomorrow I suppose.

I'll still take any pointers I can get. I've thankfully not had to do this very often.
Markopolo400
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Markopolo400 4/5/2016 7:46pm
4/5/2016 7:46pm
Even worst case you can get the shifter shaft out through the inner clutch cover. No need to pull the engine at all.

The Shop

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Paw Paw 271
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Paw Paw 271 4/5/2016 7:49pm
4/5/2016 7:49pm
Markopolo400 wrote:
Even worst case you can get the shifter shaft out through the inner clutch cover. No need to pull the engine at all.
Correct...You don't have to pull the engine or do any thing more than pull the clutch cover and the clutch to get this shaft out and replace it.

Paw Paw
beamer
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beamer 4/5/2016 7:50pm
4/5/2016 7:50pm
If the drill bit it out, and you are just dealing with a busted off bolt, I would highly recommend getting a high quality bolt extractor. Like Snap-on or Mac Tools. I've seen the lessor quality ones break on occasion.

Or.... Load it up and take to a machine shop to have them deal with it could be money well spent ! Just my 2 cents based on experience on similar problems.
Ardenb64
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Ardenb64 4/5/2016 7:51pm
4/5/2016 7:51pm
Markopolo400 wrote:
Even worst case you can get the shifter shaft out through the inner clutch cover. No need to pull the engine at all.
Paw Paw 271 wrote:
Correct...You don't have to pull the engine or do any thing more than pull the clutch cover and the clutch to get this shaft out and...
Correct...You don't have to pull the engine or do any thing more than pull the clutch cover and the clutch to get this shaft out and replace it.

Paw Paw
Thanks gentlemen. I appreciate it. I'm going to bed before I screw anything else up!Blush
Ardenb64
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Ardenb64 4/5/2016 7:52pm
4/5/2016 7:52pm
beamer wrote:
If the drill bit it out, and you are just dealing with a busted off bolt, I would highly recommend getting a high quality bolt extractor...
If the drill bit it out, and you are just dealing with a busted off bolt, I would highly recommend getting a high quality bolt extractor. Like Snap-on or Mac Tools. I've seen the lessor quality ones break on occasion.

Or.... Load it up and take to a machine shop to have them deal with it could be money well spent ! Just my 2 cents based on experience on similar problems.
Thanks Beamer!
cwtoyota
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cwtoyota 4/5/2016 9:24pm
4/5/2016 9:24pm
I would just buy a new shift shaft. I don't know how KTM is on parts pricing, but for a YZ that's a $23 part plus a $8 gasket.

Any good machine/fab shop will charge you $50 - $100 per hour; usually with a minimum charge of 1 hour.


That tapered spline is a piss-poor design. I can't believe they still use that on a $10000 motorcycle.




pete24
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pete24 4/6/2016 6:08am
4/6/2016 6:08am
i got three of those out last year layed the bike on its side and drilled them out, i didnt brake any drills tho, and ya its a shitty design
Ardenb64
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Ardenb64 4/6/2016 7:56am
4/6/2016 7:56am
Thanks everyone. I'm stopping by my parts store this afternoon to try to redrill and thread. If that gives me fits, I'll just buy a new one.

Sucks!! I wanted to ride this weekend!!
CarlinoJoeVideo
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CarlinoJoeVideo 4/6/2016 8:46am
4/6/2016 8:46am
Just keep working it. It will come out. I broke a bolt off in the countershaft a few weeks ago, but luckily got it out.
CarlinoJoeVideo
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CarlinoJoeVideo 4/6/2016 8:49am
4/6/2016 8:49am
Did you try using an easy out or reverse drill bit yet?


Ardenb64
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Ardenb64 4/6/2016 8:55am
4/6/2016 8:55am
CarlinoJoeVideo wrote:
Did you try using an easy out or reverse drill bit yet? [img]https://p.vitalmx.com/photos/forums/2016/04/06/130694/s1200_image.jpg[/img]
Did you try using an easy out or reverse drill bit yet?


That's what I plan to buy this afternoon. I'm hoping that gets the remnants out.

It's a steel shaft, so are there different threading tools as opposed for an aluminum thread?
cwtoyota
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cwtoyota 4/6/2016 12:46pm
4/6/2016 12:46pm Edited Date/Time 4/6/2016 12:48pm
CarlinoJoeVideo wrote:
Did you try using an easy out or reverse drill bit yet? [img]https://p.vitalmx.com/photos/forums/2016/04/06/130694/s1200_image.jpg[/img]
Did you try using an easy out or reverse drill bit yet?


Ardenb64 wrote:
That's what I plan to buy this afternoon. I'm hoping that gets the remnants out. It's a steel shaft, so are there different threading tools as...
That's what I plan to buy this afternoon. I'm hoping that gets the remnants out.

It's a steel shaft, so are there different threading tools as opposed for an aluminum thread?
To remove a broken bit or broken easy-out, you need carbide.
Tungsten-Carbide is the only cutting tool harder than the tool-steel your broken bit or easy-out was made of. A drill made from carbide will cut through that old bit like butter. Anything else is just going to leave you frustrated.

A "Locksmith Drill" is probably the best option. They are special straight-flute drills with a tungsten-carbide tip brazed on.

A solid carbide drill looks like a regular drill bit, but it is made of carbide.
They usually cost around $8 - $15 at a local tool supply house.

Some of the local tool-supply houses will have locksmith drills or solid-carbide drills. You won't find the good stuff at Home Depot, Lowes, Ace or any of the big chain stores.

A standard HSS (High Speed Steel) threading tap should be fine for that shift-shaft. M42 Cobalt-Steel and Carbide taps are superior to plain HSS. Cobalt will be a bit tougher than HSS, but if you don't want to fool around carbide tooling is literally twice as good (and twice the cost).
BAMX
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BAMX 4/6/2016 2:41pm
4/6/2016 2:41pm
After working on machinery for years, here are my tips for removing broken bolts, drills taps. One of the keys things is to take a deep breath and get your pilot hole drilled straight down the middle. If possible, I use a sanding wheel to make the top of the broken bolt flat and then use a punch to mark the center.

Broken Bolts: (note that heat and Kroil or PB Blaster helps)

left handed (reverse) drill bits: (start small and make sure that the hole is in the center of the bolt)

http://www.amazon.com/Tools-Cobalt-64-Inch-Assortment-30520/dp/B0002NYB…

rigid screw extractor set

http://www.amazon.com/Ridgid-35585-No-Screw-Extractor/dp/B000WQYJIG/ref…

Broken Drills and Taps:

Tap Extractors:

http://www.amazon.com/Walton-Tools-18001-Tap-Extractor/dp/B0006NGGCM/re…

Drill out tap extractors

http://www.mcmaster.com/#tap-extractors/=11va16g

IF ALL ELS FAILS, BURN IT OUT

http://www.electroarc.com/


Markee
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Markee 4/7/2016 6:22am
4/7/2016 6:22am
That part is 38 bucks, chunk it and ride LOL

While you have it out, sharpen the shifting claws for more positive feel.
ToolMaker 4/7/2016 7:08am
4/7/2016 7:08am
CarlinoJoeVideo wrote:
Did you try using an easy out or reverse drill bit yet? [img]https://p.vitalmx.com/photos/forums/2016/04/06/130694/s1200_image.jpg[/img]
Did you try using an easy out or reverse drill bit yet?


In the picture the drills shown are standard drills. I have found that many times just using a left handed drill bit
the drill actually removes the unwanted part before even needing to use the EZ-Out
TM

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Tracktor
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Tracktor 4/7/2016 10:24am
4/7/2016 10:24am
Left hand drill bits are a total life saver. Usually just using one pulls the broken bolt out. Stay away from those cheap spiral screw extractors like pictured above. I have broken way to many of those to trust. If you need to use an extractor get a 4 sided style.............
Ardenb64
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Ardenb64 4/7/2016 8:53pm
4/7/2016 8:53pm
Thanks everyone! Ended up getting the remnants out w a left handed drill bit. The threads weren't damaged like I originally thought. I'll be racing this weekend Smile
CarlinoJoeVideo
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CarlinoJoeVideo 4/8/2016 8:54am
4/8/2016 8:54am
Ardenb64 wrote:
Thanks everyone! Ended up getting the remnants out w a left handed drill bit. The threads weren't damaged like I originally thought. I'll be racing this...
Thanks everyone! Ended up getting the remnants out w a left handed drill bit. The threads weren't damaged like I originally thought. I'll be racing this weekend Smile
Boom! Nice work!Whistling Whistling Whistling

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