OK, I was reinstalling the cam shaft bearing cap & one of the bolts did not torque properly. I backed it out and the kawa bolt was stretched. I went to NAPA & got a new bolt and it kinda felt the same so I backed it out and it was OK.... so back in it went and it never seated properly either....

the bolt is sheared off even with the top of the head platform for the cam bearing cap.

How do I get it out & what should I do?

Try another bolt and use lower torque?
Drill it and tap it larger?

All the other bolts snugged down just fine. I was tightening to 8 ft-lbs.

Help.

 

easy outs work well. What grade of bolt were you using that broke off? The OEM kawi bolts are super soft, upgrading to a higher grade is most usefull. I generally stay with grade 10 on my stuff. And stay with the recommended torque specs and procedures per your manual.

 

Easy outs or if you wanted to (i've had great luck doin it) use a welder to build up the bolt material and use vice grips to get ahold of it and take it out. Just make sure you cover up yer motor to keep stuff from gettin in there.

 

wow, just reading in the klx section and now knowing that there are two different lengths of bolts. Interesting and good to know. All the more better to keep everything organized on dissassembly.

 

OK, got the head to a machine shop and he drilled the sheared bolt off. We did not have to install a keenset or helicore as the threads were ok amazingly enough.
Figured out that the main problem was using a torque wrench at it's low limit was a big problem. Ordered a new in-lbs torque wrench & reassembled and it is running good now.

I installed the 351 kit & am thinking of setting a new redline for the bike.

Does anyone know what the wt is for the stock kawa piston in grams?

 

wow, no idea on that grams question. But, congrats on the head fix.