I recently had to tighten my chain on my 660 & low & behold the one of the chain adjuster bolts broke on me while tighten. Too deep to use vise grips to remove I had to get a reverse drill bit to remove. I end up getting a Craftman bolt extractor, however it grip the bolt but not good enough to remove, it seems like the bolt is seized in & I have no way of removing it. Because of the angle, it's quite challenging to work in those quarters. Anyway experienced any problem like this b4, if so how did you resolve it? Or tips or advice on getting that bolt out?

 

I wouldnt take this advice without consulting a professional but I would consider drilling it out big time I mean put that bolt in pieces without hurting any of the internal structure then use a magnet to remove all the pieces; that could maybe work?????????? (I dunno) but a suggestion would be to replace those bolts after every chain you buy if not more often than that they are relatively inexpensive and if my first idea sounds to risky I would take it to the stealership and see what they could do...Man that sucks I feel bad for you

 

Cutting pieces is gonna be close to impossible @ that angle..And if I take it to the steal-a-ship, I'm sure it's gonna cost me around 1K to resolve since they bill by the hr. Any other suggestion anybody might have? I'm really starting to hate this Raptor. It's one problem after another.

 

Can you get enough access to the remaining bolt to weld on another bolt to it?

 

no, the bolt is broken half way down in the threads.

 

Ahhhh..... I knew I wasn't the only one. Unfortunately, I don't think you're going to go with my solution, which was to put an LSR swingarm on it. If I had to do it again I would go with Walsh or Roll Design, but anyways...

Here's one solution. Take the swingarm off, it's really not that bad. Gives you a chance to inspect and replace your axle bearings, swingarm bushings and pivot bolt. Drill out the broken bolt. Get a heli-coil kit and re-tap it for the heli-coil (make sure to get one that matches the bolt size, so either buy a new bolt from Yamaha, which is around two bucks) and put it in. Use a little lock tite, and it should be good as new. You can probably do without the lock tite here, considering there is a lock nut. But it's up to you.

 

You might want to try an easy-out. You gotta drill into the bolt, with a titanium or better bit. the bit should be about half as small as the bolt you are trying to extract. then you insert the extractor that will be matched to the size of the drill bit you use. ACE has as great selection of these by the way, home depot does not. Put oil on the bolt as you are drilling, this will help keep the bit from going dull / getting too hot. wD-40 works great. When inserting the extractor you need a tool that looks like a drill head with a t-handle that you sit the extracter in and tighten down... you can find this at the hardware store, then, put the extrator in the hole you drilled as straight-up and down as you can get it, vertically level as you can get it to the bolt thats stuck, turn the extractor the opposite way slowly, like if you where trying to tighten the bolt. Use lots of WD-40...it penetrates and brakes it loose. WHATEVER you do! DO NOT break the extractor off in it, I did that the first time i ever tried to extract a bolt and they are impossible to drill past with any bit. I have done this a lot, as I have a problem with breaking lots of bolts but I can always seem to get them out this way...good luck...also you might want to try MARTINO's suggestion and if you mess the threads up a little, you can always re-thread it. good luck - peace

 

Thanks for the advise guys. I was thinking about taken the swingarm off, but dam that's alot of work. Not to mention I had to take the axle off to change the bearings & oil seal like 2 weeks which was a mission & a half due to the seized axle nuts. I'm gonna get one of those DeWalt right angle drills & drill out the bolt, & get one of those heli kits & rethread it. Finding the bolt shouldn't be too much of a problem. Does anybody know what Heli-coil kit I should purchase for that size thread?