busted bolts in crackcase help

[74sickness]

So i have been have oil leaking problems on my 83 200x and i put new gaskets in but its still leaking a little bit and one know some quick fixes and back to my original question, I over tightened some bolts on my crankcase and snapped 3 whats the best way to approach this by drilling the broken part out and re tapping? Thank you

[ps2fixer]

I think it depends where it snapped off. If it snapped flush to where the threads start in the case, I would say drill/tap, however... if it broke off say half way up, taking it apart and removing it seems to be the "best" option, might not be the quickest though :(.

[tri again]

You mean those 6 mm side cover bolts? Like 3 out of 10 or 12?

I'd be tempted to take the cover off and hope that the bolts can be grabbed with
some sort of cam 'shaft' pipewrench type tool and just spin right out.
Remember an ez out or left handed drill bits are HARD and if they break off, there is no real support group for that anymore.

and make sure they are in the right positions..some may be shorter or longer and some may bottom out and break easily too. (pls don't ask how I know that)

Whatever you do, be careful and super sparing with any gasket sealer.
I usually don't use any, but glue the gaskets to the case, let it dry dry and then
a Very little sealer and let that dry dry dry too so it's like pinching a rubber band.

Keep us posted, I'l bet you get lucky and it's a non issue.
Tighten the cover bolts a little at a time and go around about 10 times until they are all snug.
I bet there's an actual torque spec in the
service manual

Be careful, good luck and keep us posted.

ps - you sure the case doesn't have a little crack? or shift shaft seal leaking?
or tracking oil from some place higher?
vent tubes crankcase plugged? etc etc

[Gripit'n'ripit]

I like Tri Agains advice. Removed a decent number of bolt from lots of machines in that manner.
It brings joy to know other people have left handed drill bits. I asked for them at an ACE hardware once. The employee thought i was playing a joke and becasme a little less than pleasent.

[ps2fixer]

Some photos would help too. I'm not sure how close the 200es engine is to the 200x, but I suspect the case screws might be close. If you can find the specs, I can check the bolts I have from a 200es.

[tri again]

I like Tri Agains advice. Removed a decent number of bolt from lots of machines in that manner.
It brings joy to know other people have left handed drill bits. I asked for them at an ACE hardware once. The employee thought i was playing a joke and becasme a little less than pleasent.

Tanks mang,

I got mine from the mac guy.
IF we're lucky, sometimes they'll drill a little and bite and spin the bolts right out
IF they don't snap off.

I bet NAPA has them too but I'd buy the good ones.

Hopefully he can just grab 'em with vice grips.

Your ace guy was probably having flashbacks from summer camp when he was sent to get a 'left handed smoke shifter'.

[ps2fixer]

Tanks mang,

I got mine from the mac guy.
IF we're lucky, sometimes they'll drill a little and bite and spin the bolts right out
IF they don't snap off.

I bet NAPA has them too but I'd buy the good ones.

Hopefully he can just grab 'em with vice grips.

Your ace guy was probably having flashbacks from summer camp when he was sent to get a 'left handed smoke shifter'.

Don't forget the cable strecher to go with that!

[Flyingw]

The issue here is how to get the bolt shanks out of the case. If the bolts snapped off because of boogered threads then drilling them and using an easy out is the way to go but when the bolts snap off because of over-tightening, the shank of the bolt most times do turn easliy. The trick is to grab the shank in some manner. Sometimes its as easy as pressing your thumb against the snapped off shank and turning it. Other times simply drilling it with a left hand drill will turn the shank right out with little or no effort.

This is a good wakeup call. The 6mm bolts only have to be tightened to 6-9lbs of torque. Not very much. Tightening the snot out of them only leads to broke parts, broke bolts, and more work.

[74sickness]

^ I found that out the hard way since i was leaking oil i was like i think they have to be tightend more but i guess not, From where the bolt snapped off i was just thinking that if i take half the engine cover off i should be able to just get vice grips and spin them out. Reason being is because all the bolts snapped off right at the ends so there should be some sticking out that i can grab. And tri again i would defiantly try that method on the gaskets and i hope it will fix my problem. Also at ps2fixer im pretty sure the 200es motor and the 200x motor are the same (correct me if im wrong) But the only difference i see is the 200es is an automatic and the 200x motor is manual. Ive heard of people swapping there engine on a 200x to a 200es to get an automatic x but of course automatic is boring when you a whipping through the trees. If you have extra bolts please pm me maybe we can work something out. Thank you everyone for your replies.

[ps2fixer]

I think you might be missing up the 200es with the 200s, es is shaft drive, s is the same engine as the x except it has a cooler cam, and lower compression and the "hondamatic" transmission. The 200es I think is similar, but the shaft drive version. Either way, I don't see Honda making 8000 different bolt types for a simple case bolt. If you can get a measurement on the length, and diameter of the bolt and I can check what I have. I have parted a couple of engines out lately, so there is a chance I might have something good :).

[Dirtcrasher]

Did you clean and wire wheel the bolts threads and run a clean up tap through each 6mm x 1.0 pitch threaded holes??

That has to be part of the "program" as well as grease on the threads and grease the gaskets when putting all back together.

Always use a short 1/4" ratchet on smaller bolts; This helps considerably to keep from over tightening them, or a torque wrench.

Most likely dirty bolt threads and case threads caused this. If the snap from corrosion even a LH drill bit won't come back out easily.

[tri again]

DC has the final word I forgot to even consider.
I forgot about corroded threads but then again, I always wire brush them and have been known to use anti seize.

Always great to have a few different approaches.

Thanks for catching that , DC.

[hoosierlogger]

I put anti seize on everything. Why? cause I may be the poor SOB that has to take it apart next time.

You might be able to cut a slot in the end of the bolt with a dremel, and use a small straight screwdriver on it.

[74sickness]

^ Good point i will try that when it gets warmer as it is quite cold in toronto to lol Thank you all for your suggestions.

[Dirtcrasher]

What funny is I clean up whatever I'm tackling and then everything else will break :lol: