What do I do about a snapped bolt in my clutch basket?

KxCm545
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KxCm545

I was replacing my clutch plates on my kx250f and my bikes clutch uses a spring disc instead of clutch springs so it’s kind of strange. Any way I was tightening the spring bolt thingys up and to 9nm but I must’ve made a mistake with the torque wrench because one of the bolts decided to snap. There is no bolt exposed and I’m literally about to throw my whole clutch into the bin. Any suggestions on what to do?

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Mr Happy
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Mr Happy 3/21/2023 4:48am
3/21/2023 4:48am Edited Date/Time 3/21/2023 4:49am

If the bolt holes are through holes, you can see the other end of the bolt, I had success with a round bit of wood in a drill on the back of the bolt and friction winding it out. Or even give it a go from the snapped end if they're not.

freelancer alpha 1-1 3/21/2023 6:59am
3/21/2023 6:59am

I had snapped bolt in clutch basket on 2010 kxf250. Snapped at less than 10Nm. But I was lucky, because thread is clean and oily, so I could use a metal sharp pick to rotate leftover piece.

40acres
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40acres 3/21/2023 7:23am
3/21/2023 7:23am

There are many ways to get that out, so fear not. Depending on your level of expertise and tools you have. The easiest and most successful path would be welding a nut onto it and rotating it out. Another method would be drilling it out and using easy outs to rotate it back out. Milwaukee makes a good set of metal drill bits that I have had great luck with. 

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Moto520
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Moto520 3/21/2023 8:40am
3/21/2023 8:40am Edited Date/Time 3/21/2023 8:41am

Don't freak out.....easy enough fix.  We will talk you through it.  Get us a photo of what you are working with if you can.

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harescrambled 3/25/2023 3:25pm
3/25/2023 3:25pm Edited Date/Time 3/25/2023 3:25pm

A left handed drill bit may work out for you

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BAMX
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BAMX 3/26/2023 2:24pm
3/26/2023 2:24pm
harescrambled wrote:

A left handed drill bit may work out for you

This...start with a center punch to help keep the bit from walking.  As this broke tightening it up, you have a really good chance of getting it out.

sandman768
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sandman768 3/26/2023 3:37pm
3/26/2023 3:37pm

As already stated, take a photo for all to see, if it’s the center hub, they are usually pretty cheap to replace new….

Gravel
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Gravel 3/26/2023 9:02pm
3/26/2023 9:02pm

Agree with left hand drills, they can make broken bolt removal easy. Sometimes.. 

Dirt.Squirt
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Dirt.Squirt 3/28/2023 12:26am
3/28/2023 12:26am Edited Date/Time 3/28/2023 12:26am

Did this literally a week ago. Take a small chisel and hammer a flat head screw driver slot into the bolt not ideal but its another option 

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