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August 20th, 2019, 07:34 PM   #1
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I Ride: 95 FE350 / 99 FC501
1999 FC501 broken bolt for kickstart

Hey Everyone. Found this bike locally for cheap. It had a rough life.Previous owner broke the kickstart gear and one of the screws for the retaining plate. The screw broke off in the hole. Any ideas how I can get this Screw out without splitting the cases? You can see whats left of the screw in the pics. Its one of the two countersunk phillips heads screws that hold the retaining plate for the kickstart assembly. He tore the case up quite a bit as well, but no cracks. Hopefully I can salvage it.

1999 FC501 broken bolt for kickstart-img_3657.jpg

1999 FC501 broken bolt for kickstart-img_3656.jpg

1999 FC501 broken bolt for kickstart-img_3655.jpg

1999 FC501 broken bolt for kickstart-img_3662.jpg
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August 21st, 2019, 07:31 AM   #2
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I take it the bolt broke in use? If so, you might be lucky and it might not be stuck. I'd take a pick and see if you can get it to rotate at all.

If that doesn't work, take a die grinder and flatten the broken section, then a center punch and put a dimple on it, then use a left handed drill bit somewhat smaller than the minor diameter of the bolt to try to remove it.
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August 21st, 2019, 07:53 AM   #3
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because it broke due to percussion, it will unscrew using a steel pick-point.

get yourself a new sledge plate with Torx screws (which i do as a modification)

if you need a kickstart gear i have them (used) but I don't think you meant the gear.

Taffy
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August 22nd, 2019, 09:22 PM   #4
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Originally Posted by Junkie View Post
I take it the bolt broke in use? If so, you might be lucky and it might not be stuck. I'd take a pick and see if you can get it to rotate at all.

If that doesn't work, take a die grinder and flatten the broken section, then a center punch and put a dimple on it, then use a left handed drill bit somewhat smaller than the minor diameter of the bolt to try to remove it.

I Bought the bike with the damage already done, owner says he was trying to start it when it happened. When I got the bike the clutch cover was already off and torn down. The pics are from the day I brought it home. I'm hoping a pick will get it out, as its broken off up inside the hole. Nothing is sticking out to be able to get a grinder on it. Its a very tiny/short screw, so you dont get much to work with.
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August 22nd, 2019, 09:28 PM   #5
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Originally Posted by Taffy View Post
because it broke due to percussion, it will unscrew using a steel pick-point.

get yourself a new sledge plate with Torx screws (which i do as a modification)

if you need a kickstart gear i have them (used) but I don't think you meant the gear.

Taffy
Thanks Taffy, I'll give it a go and let you all know how it goes getting it out. I'll post a pic of the broken parts this weekend. You are correct, I was just generalizing. The gear itself is fine, its part of the shaft that broke. I'll be picking up a sledge plate from you as well in short order. I'll also post pics of the parts the previous owner removed to make sure I'm not missing anything. I really wish he had just left the engine assembled. I hate knowing stuff could be missing on an engine I'm unfamiliar with. I'll update this weekend, Thanks again for replying!

Tim
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1999, bolt, broken, fc501, kickstart



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