In going over my bike before the weekend ride, a fastener that holds my chain slider snapped off flush with the swingarm. I barely touched it, so it was probably a faulty fastener. I have it zip tied for now, but would like to get another fastener in there. I can't get a drill bit to bite into it. Any suggestions? Thanks!
Is the fastener on the top or bottom of the chain slider? I only bring this up because if it is on the top, and you don't replace it before your next ride the chain can pull the slider into the front sprocket and cause problems. On the bottom is less of a worry because of the direction the chain is going, but should still be replaced. As for getting it out, if it is broken off at an angle use a file to file it flat as possible. Next take a punch and make a dimple in the center of the broken bolt. Now using an 1/8th drill bit drill down the center of the screw as straight as possible. Keep drilling out the screw with larger and larger drill bits until you only have the threads left. Take an m6 x 1.0 tap and clean out the old threads, and reinstall a new screw.
It is on the top, toward the rear. I feared what you have suggested, which is why I got the zip tie on it. It lasted the day of riding I did on Saturday, but I wouldn't want to risk it for too long. I had tried dimpling it which stopped the bit from wandering, but it still wouldn't bite into the fastener. I think I need a harder/sharper bit. Thanks for your help!
I had something like that happen one time. Had an old bike that the upper chain guard got brittle on. It simply came apart at the screw and nothing was holding it in place at the back end. I ended up using silicone RTV to hold it in place till I got it fixed and that held for four years! (I had to wait for somebody to manufacture an aftermarket set of guards because the OEM ones were no longer available) Use a nice titanium drill bit to get things going after you have used a centerpunch tool.
For me...the best way to remove a broken bolt that is flush or even below flush....find a nut with a thread size similar to the broken fastener... hold it in place over broken fastener with vise grips or a screwdriver blade.... use mig welder...ground cable close to area(unplug CD box as a precaution) arc the inside of the nut to top of broken fastener....remove with wrench the added heat helps back it out too....
Nice suggestion Troy.. If it is the sheet metal bolt/screw type I snapped one off on our 1st 2010 TE 250 and just took the pointed punch and tapped it twice and it fell in( I was hoping never to hear it rattling around) and I never did.. I guess it founds its way back to the rear of the swingarm and stuck fast.. Chow, Carl
The welder method works too if you have access to a welder. If you can't get the screw out, just drill and tap 2 new holes through the chain slider into the swingarm, one on either side of the existing hole. Then countersink the chain slider and use a tapered screw to screw into the swingarm so the head sits below the surface of the chain slider. Or do as dirtdame did and glue it on. Seemed to work for her.
Okay, I managed to drill it out starting with a slightly larger bit. Thanks for the excellent suggestions, all! Oh, and Dirtdame, I had considered using silicone, but wasn't sure if it would hold. Now I know!
