I successfully adjusted the valves on my new Rancher at 150 kms which is what is recommended in the shop manual. I somehow managed to over-tighten one valve cover bolt and broke it. Anyone done this - how can I get the remains of the bolt out of the cylinder head without causing further damage.

 

Well was it broken off below the top of the cylinder or is there a portion still sticking out? If there's anything to grab onto, lock a vise grip on it and it should back out. If it's below the top of the cylinder head then it will take a screw extractor or ez-out as some people call it to get it out. You have to drill into the bolt with a smaller diameter bit and then the ez-out goes into that hole and is threaded so it will grip the bolt when you turn it counter clockwise and that way you can back the bolt out. You need to be careful though so you don't booger up your cylinder head while doing this. If you don't have a steady hand or don't feel comfortable doing it then the dealer or any automotive machine shop should be able to do it for you. If you do it yourself make sure you buy a good quality screw extractor and use a good drill bit. You can buy cheap ez-out sets but alot of times they will snap off before breaking the bolt loose and then you're in worse shape than before. Usually auto parts stores carry decent screw extractor sets. Good luck with it.

 

Its broken off almost flush with the cylinder so I'll buy that e-z out you mentioned or maybe I'll play safe and take it to the dealer (depending on what they charge). Thanks for your help.