New project Bike

I’m guessing that that part of the engine is ruined because after looking at the other exhaust stud holes, they only go about an inch before you run into solid metal... I drilled through that and went straight to the spark plug. Someone mentioned hitting an oil passage if I drill too deep.

Turns out I did drill a little bit too deep. Drilled a hole through the spark plug and the threads for the spark plug.

[Rich82GS750TZ]

You shouldn’t need to take the engine out of the frame to remove the head (unless you’re looking for more work). If you do take the head off, common wisdom says to go ahead and remove the barrels so you can replace the base gasket as well. Base gaskets are prone to leaking once the head has been removed (so I’ve read). Take the opportunity to rebuild cam chain tensioner. Replace all gaskets from the base up. Isn’t it great how one thing leads to another?

Because I had to drill a size larger to get the remaining bolt bits out, I need to pull the engine Out of the frame and check if I accidentally drilled through anything important in there... don?t know why I thought it would be okay to drill deeper and deeper cause someone said ?go up a bit size and go deeper/ repeat till bolt comes out? for some reason I followed that advice too literally instead of using common sense... But I need to disconnect the shaft drive. I?ve removed all 8 bolts down there underneath the rubber boot. How do I disconnect it?

Before joining this forum I used a screw extractor to remove a snapped off bolt on the starter motor cover. It promptly snapped leaving me with not only a broken bolt but a snapped off extractor as well. There was no way to get it out as it was hardened steel and could not be drilled out. Fortunately there was enough aluminum to drill down underneath beside it with a tiny drill bit from 3 spots. I then tapped the bolt and extractor down into the casing re tapped the enlarged hole and installed a shorter bolt. It was a lesson learned and never forgotten .Will never use those again!

[wymple]

Nobody, IMO, should try extracting screws without a visit for an hour or so to You Tube to watch & see what others do. Much better than attacking a touchy little mess with no experience.

[Big T]

Tried the reverse drill bit. A bunch of bits of bolt Came out, biggest bit in the kit is still barely not big enough so there?’s still bolt In there... do I just buy a larger drill bit And keep drilling ?

Yes, but check your depth. If you drill too deep, you could hit an oil passage.

[Grimly]

Thanks for the advice. How should I actually get the last bits out? Just drill it all the way through?

That's what's worked for me most times. Get a set of Left-hand drills in staged sizes.
Sure, I've had the odd success with extractors, but not that type. In fact, that type of extractor is notorious for breaking off and leaving you with a worse problem.

The best way of using those screw extractors is to carefully grasp them in your left hand and with your right, open the lid of your bin and drop them in with your left.

Thanks for the advice. How should I actually get the last bits out? Just drill it all the way through?

[Grimly]

The best way of using those screw extractors is to carefully grasp them in your left hand and with your right, open the lid of your bin and drop them in with your left.

I was told to try one of these kits885911591317 by David Torres, on Flickr
Here is the oil strainer885911591317 by David Torres, on Flickr
Notice the scratches inside the oil pan in the next 2 pictures(is this something to cause alarm)IMG_0235 by David Torres, on IMG_0236 by David Torres, on Flickr
The seat pan IMG_0198 by David Torres, on Flickr
Front fender chrome is in terrible condition, wonder if there is a way to remove the chrome plating and just paint it to save the part...IMG_0189 by David Torres, on Flickr

Cleaning up the black dried up oil pan &other covers with the same stuff. Using simple green and dawn soap Finished with brake cleaner. Also trying to salvage the slightly rusted handlebars with steel wool & polish. Still haven?t got the broken exhaust stud. It?s basically just a hollow bolt left in there now.

Tried the reverse drill bit. A bunch of bits of bolt Came out, biggest bit in the kit is still barely not big enough so there?’s still bolt In there... do I just buy a larger drill bit And keep drilling ?

[Big T]

Get some reverse drill bits at HF
Center punch the bolt
Using the smallest bit, create a perfectly centered hole, then drill in a half inch or so, lubing as you go
Go up a drill size and go deeper
Repeat until the bolt remnant spins out
Do not use an EZout
If you're good, no tap needed

I plan on starting the engine first . My first step I initially wanted to try and get this broken exhaust stud out, but after doing some searching I think it might be better to take the head to a shop to have them remove it. It?s broken off flush so from what I?m gathering from other searches the favorite method here is to weld a nut on. Second option is to drill out and Tap. Ez out is not a good option. Tough decision... any suggestions