Broke an "easy out" off trying to remove bolt - Honda ATV Forum
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post #1 of 31 (permalink) Old 10-12-2010, 08:53 PM Thread Starter
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Broke an "easy out" off trying to remove bolt

I need help ... I broke an "easy out" off trying to remove a broken bolt. I know these things are made of really hard metal and are almost impossible to drill out. I have tried drilling out around the "easy out" with small drills; however, not having any luck.

Can anyone suggest a way of getting this hard metal out ??

thanks in advance,

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post #2 of 31 (permalink) Old 10-12-2010, 08:56 PM
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It will be hard to get out. The easy out is harder than the drill bits. You might keep drilling and get it out, but it would take a lot of bits, they'll keep breaking or getting dull.

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post #3 of 31 (permalink) Old 10-12-2010, 08:57 PM
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Originally Posted by gcsb77 View Post
I need help ... I broke an "easy out" off trying to remove a broken bolt. I know these things are made of really hard metal and are almost impossible to drill out. I have tried drilling out around the "easy out" with small drills; however, not having any luck.

Can anyone suggest a way of getting this hard metal out ??

thanks in advance,

gcsb77
man...thats a tough one..i really don't have a answer for that ..seeing how i never use those easy outs..i've never had one break on me..lol..what did you break it off into ?

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post #4 of 31 (permalink) Old 10-12-2010, 09:03 PM Thread Starter
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1985 TRX 250 exaust pipe. The small carbon purge plate close to the muffler exit that you are supposed to remove peridically to blow the carbon out. One of the two bolts broke off even with the muffler metal. The broken bolt is attached to a nut on the backside of the muffler metal.

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post #5 of 31 (permalink) Old 10-12-2010, 09:14 PM
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1985 TRX 250 exaust pipe. The small carbon purge plate close to the muffler exit that you are supposed to remove peridically to blow the carbon out. One of the two bolts broke off even with the muffler metal. The broken bolt is attached to a nut on the backside of the muffler metal.

gcsb77
well crap..you got two choices..leave it be..or..take a dremel with a cut off wheel..cut the bolt off flush with the muffler..if it was me..i'd leave it alone..it won't hurt anything to have that easy out sticking inside the muffler...if you decide to use a dremel with a cut off wheel..those things are pretty high speed..it may cut the easy off too ?.

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post #6 of 31 (permalink) Old 10-12-2010, 09:36 PM Thread Starter
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Had not thought about the dremel tool. thanks for the idea. Need to check to see if I have a cut off wheel.

The thought I had was to replace the purge plate to stop the exaust gases from discharging straight down toward the rear brake adjustment springs and wing nuts. However, maybe the amount of exaust and temperature of the gases is not enought to hurt anything .... might cause a little rust but can keep this area coated with oil to stop the possibility of rusting.

thanks,
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post #7 of 31 (permalink) Old 10-13-2010, 05:43 PM
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You could try a propane torch. If the 2 metals are different compounds, one will expand quicker than the other and may just give you enough play to remove the broken "easy out".
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post #8 of 31 (permalink) Old 10-13-2010, 07:52 PM Thread Starter
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unfortunately the easy-out broke off even with the surface and cannot get pliers or anything to grip it. The idea of using a dremel tool with a cut-off wheel didn't work either because the easy-out is not sticking out from the surface of the muffler.

So others don't make the same mistake, DO NOT buy an easy-out at O'Reilly's for $2.97 each. They break very very easily. They must be made of glass!!!!!! I just barely applied a little torque and it snapped like a peanut hull.

For future use, I went to Home Depot today and purchased a Black and Decker set of easy-outs and some cobalt drills. It don't pay to scrimp on tools for sure.

My goal is to drill down beside the easy out enough to get another easy-out to grip again.
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post #9 of 31 (permalink) Old 10-14-2010, 12:06 AM
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unfortunately the easy-out broke off even with the surface and cannot get pliers or anything to grip it. The idea of using a dremel tool with a cut-off wheel didn't work either because the easy-out is not sticking out from the surface of the muffler.

So others don't make the same mistake, DO NOT buy an easy-out at O'Reilly's for $2.97 each. They break very very easily. They must be made of glass!!!!!! I just barely applied a little torque and it snapped like a peanut hull.

For future use, I went to Home Depot today and purchased a Black and Decker set of easy-outs and some cobalt drills. It don't pay to scrimp on tools for sure.

My goal is to drill down beside the easy out enough to get another easy-out to grip again.
to save you alot of trouble..here's what i would do..i would take a cut off wheel for the dremel..slice out the whole purge bolt thing..then..with a piece of tin..and some jb weld..i would cover that hole up..and never worry about it again !..lol.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '05 trx500fm

Last edited by shadetree; 10-14-2010 at 09:50 AM.
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post #10 of 31 (permalink) Old 10-14-2010, 08:32 AM
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Just for giggles, the spark arrester is required to ride on some/many state lands, so if you plan to ride state land, don't alter the pipe. Just leave it alone as if nothing was ever done to it and no one will be the wiser.

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