Snapped Cam Cap Bolt / Help

[Irish_Alan]

Hey guys,

Got a real ball buster of a problem.

ZXR 250 C1 (equivalent of a L1) I was replacing the head gasket, and I was tighten down the cam cap (Its all one unit).
Done the sequence 1-16 by hand, then nipped them tight with a rachet. Then the torque wrench 4.3 foot pounds.
The bolt 'felt' good but was not clicking then SNAP.

Broken No.1 bolt :smt013

What now !?
Advice please.

Take it to an engineers to remove the 10mm of bolt in the head ?

Should I suspect my torque wrench ?

And has this happened to any ZXR-4 owners ?

Thanks guys.

[RedexRobB]

Not sure what it all looks like, but if the bolt head has snapped then id take out the remaining 15 bolts, to lift it all off then use a stud extractor to get it out if its tight. Or maybe even mole grips could do the job if theres enough sicking out.

[lewisdale]

another idea when your about to extract it with a stud extractor is to buy a freeze spray, u can get it from most car spares shops

[Irish_Alan]

Sorry,

I was so furious saturday I have not seen the offending bolt since, and wont till next weekend. I have been pondering it and I think most of the bolt left should come out by hand or at least with some assitance from a vice grips. I'll let you know on the hoildays.

And has anyone posted any information about the ZXR-250 ? or is it a tabbo subject - never again to be mentioned...

[RedexRobB]

Not taboo at all mate

Be good to have some info on it actually, expand the site a bit more, we have a 750 section recently added. Not very often, but we do get ZXR250 owners here askin questions, but since were not 250 oriented we dont really know much about them.

[cargo]

A broken bolt is a broken bolt don't matter what the bike is.


Really depends on how much of the broken end is exposed............... I've sheared off bolts and found the broken end to be lose and finger tight !

If there is enough to get a good grip with vise grips then good but make sure your using vise grips that have nice sharp teeth to give it a chance of gripping old knackerd worn ones are................... pants.

If it wont move don't just keep on with the vice grips........try a heating the area around the broken bolt a hot air gun is good for this..............a drop or two of that freezing sprap on the bolt itself will help reheat and respray a few times. If you are getting a good grip with the vice grips it should come out....................

If there's little or nothing to grip.........................

You can get easizie outs tapered left hand thread inserts the you need to drill a hole into the broken end then screw the eazie out into it's left hand thread will tighten ot come the broken end.....................in theroy. The problem with these is that with smal broekn bolts the taper expands the broken bolt making it tighter in the hole.
What ever you do do not break the eazie out.

The probelm you have is that what ever you do you need to make sure you get you cam caps back in place perfectly. I've fixed broken bolts that wouldn't come out by grinding the whole thing away and refilling with ally wielding then drilling and tapping it was a bodge and it was an exhaust port stud so getting it perfect didn't matter but with cam caps they need to be perfect

Are you anywhere near Belfast ?

[Irish_Alan]

Its Out !

I removed the cam cap - there was about 3/4 of the bolt most of which was above the head. It was only finger tight.

So I have a replacement ordered, and I'm now looking for a quality Torque wrench (I suspect the first was the source of my problems).



I would be glad to help gather some information out the 250. I think most would be surprised how similar the 400 and 250 are.
I think the some suspension components are similar, but most parts are down sized - carb's are Keihin CVK 30 for example.
Who should I get in touch with about this ?


Cargo - Im out west in Mayo, do you race a ZXR ?