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Broken bolt

Discussion in 'XJ Technical Chat' started by Cody Whittington, Apr 23, 2021.

  1. Cody Whittington

    Cody Whittington New Member

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    So I was going to rebuild my starter because it keeps slipping, long story short I didn’t read directions and ended up breaking this bolt. I didn’t put much pressure on it at all and it snapped. Can someone please steer me in the right direction to get the remaining bolt out?
    It’s about at 6in bolt and the bottom portion is what broke.

    The opening is where the starter was at to give a reference where the bolt is.
     

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  2. Cody Whittington

    Cody Whittington New Member

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    It’s a 1985 xj700 btw.
     
  3. JBurch

    JBurch Active Member

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    It ain't gonna be easy.........Can you get a hand drill over the hole? If you can, get a drill bushing that has an OD equal to the OD of the bolt that snapped, ID of the bushing I'm gonna guess that a 1/4 inch would work. The bushing will guide the drill bit so you drill the center of the broken bolt so you can use a bolt extractor. I would even be tempted to use a left handed drill bit, it could catch and screw the broken piece right out.

    Above all, slow and steady are the key words here.

    Good luck!
     
    Cody Whittington likes this.
  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    how much of the bolt is in there a pic of broken bolt would show us. looks like it snaped at the threaded portion..
    I think that is going to require splitting the cases

    I would start by soaking it with pb blaster or kroil (penetrating oil) daily befor starting any attempt to drill it out with a left handed drill bit

    maybe plug the hole and ride it as is
     
    Last edited: Apr 23, 2021
  5. Cody Whittington

    Cody Whittington New Member

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    I should be able to get a drill over it. Thankfully I already had the carbs off too so that’ll help!
    Thank you!
     
  6. Cody Whittington

    Cody Whittington New Member

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    I’m not
    I’m not sure exactly how much is left in there. I’m guessing 1/4-1/2in maybe.
     
  7. Cody Whittington

    Cody Whittington New Member

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    Here’s a pic of the bolt.
     

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  8. XJ550H

    XJ550H Well-Known Member Premium Member

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    this an airhead or watercooled 700?

    buy the replacment bolt first to see what your working with/against
    did any of the thread come out?..


    looks like a 6mm diameter, you did get some of the threads out

    maybe you can still thread in a bolt and shorten the threaded length i know it is a hack move but if you try to drill down and the case threads are exposed you may mess them up
    so you realy need to know if a new bolt can thread down the hole first so you know what damage you may do
     
  9. Cody Whittington

    Cody Whittington New Member

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    Air cooled. Some of the thread did come out but it barely turned when it snapped so I don’t think much of the threads that were actually screwed in came out.
     
  10. Cody Whittington

    Cody Whittington New Member

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    From everything I’m finding replacement wise it’s showing the bolt is a 6in bolt. Meaning there is still about 3/4in left in there.
     
  11. Cody Whittington

    Cody Whittington New Member

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    You said I could plug it and drive it as is? When I pulled the bolt out it had oil on it, is there any real significance to that bolt?
     
  12. XJ550H

    XJ550H Well-Known Member Premium Member

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    problem your going to have is finding a left handed drill bit that long to do the job. I doubt you will be able to fit of find an easy out that long.
    if you are sucesful in finding the tools you may mess up the top threads.

    1 this is a case splitter for best results.
    2 next would be seeing if replacment bolt will thread in and how far/many threads it catches.
    may be possible to shorten bolt and install.

    3 replacment motor may be the cheapest way out of this.

    4 plug hole and ride it as is
     
  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    yes it is holding the cases together likely securing a bearing in the transmission.
    or secures the starter clutch
    see if you can find a sp;it up 700 motor on ebay and you will be able to see what eactly the bolt is securing.
    i am looking now
     
  14. XJ550H

    XJ550H Well-Known Member Premium Member

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  15. Cody Whittington

    Cody Whittington New Member

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    I don’t think that’s something I want to get into. I also don’t want to try to drill it and possibly ruin it even more. I’m going to try and get a replacement bolt and see if I can get it to catch even if it’s just the slightest. If that doesn’t work I’ll seal it and ride! (Hopefully).
     
  16. XJ550H

    XJ550H Well-Known Member Premium Member

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    you could measure the hole and tap the top for a plug.

    I do not suggest new cases if you were to price it out a replacment motor would be cheaper.
    this would give you time to fixx the motor you have.
    even a 750 motor would fit.

    problem with the 700 motor is piston rings are not available.
    it may be possible to swap top ends from the 700 to the 750 and make it a 700(more hp) not sure as it seems to be uncharted ground.
     
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  17. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    What you need to do is pull the engine and take it to a machine shop. That bolt does more than just hold the starter on.
     
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  18. Cody Whittington

    Cody Whittington New Member

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    Thanks I’ll probably end up doing that.
     
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