Primary Clutch Bolt Broke

[hensons700v]

I need some big help
I was taking my primary clutch bolt out to install a clutch kit in doing this i noticed that the bolt was way harder then last time to take out 2 seconds later it snapped off with about half of the threads left in it

How can i get the rest of this bolt out

[BossMan]

Where exactly did it break ? Threads in the crank. Drill pilot hole & use an easy out.

[hensons700v]

Well i would guess that it has half inch of threads still left on the bolt
But it broke off up in there deep with only like other half inch of threads still left in the bike

Cant find an easy out long enough tried calling a few places for them

never used one
so dont know how to extend an easyout to that long if it is possible

[MetalAlien]

sell the bike, it will be less frustrating than fixing that!

[Jim]

Take a bolt the same thread center drill it in a lathe so you hit center hold it strait with a drill the bolt you screw in is the fixture center point ....easy out it ...if its acts like its two much and can break the easy out jack the bike up on the left side ...take small propane torch heat the bolte bolt up at 200% dont damage the seal and melt some bees wax in it...let it cool and then easy out it...it will come right out....now let me explain why this happpens ...kawie puts that bolt in dry and it stretches...like .040 ..needs .010 ....it can bottom out ...you need to use a drop of oil on that bolt and and torque it at 66 ft # and lube the washer...dry bolts dont torque right with dry washers...Take turtle wax and wax that taper on the crank and let it dry...wipe it off ...clutch will never stick to the taper but wont slip...this works one 100hp units ...much more hp we will be keying them with a woodruff key...meanwhile thats protocol and it works...JH

[bonestockklx]

If you can get the clutch off, there might be enough bolt sticking out of the crank to grab witha GOOD pair of channel locks ( like Knipex). Don't forget that the bolt is a left hand thread also. Don't even bother with an easy out. it is just going to break off and you will have even more of a mess on your hands. Ezy outs are for right handed threads so don't even try, even if you could find one of the ellusive left hand ezy-outs. Try using a three jaw puller to get the clutch off.

Jim, woodruff keys are for timing and locating purposes only. They offer very little or no resistance to slipping. If a clutch or flywheel wants to slip, it will shear a woodruff key smooth of without hesitation. That is why there isn't one on there already. The clutch is not timed with any other componant. No need for a key. The only reason your old chevy or ford v-8 is keyed at the end of the crank is because of the timing mark on the harmonic ballancer.

[BossMan]

When I take my clutch off I insert the puller bolt & totque down on it, them smack the bolt it with a dead blow hammer & it pops right off.First time I pulled it I thought oh Chit I broke it, sounded terrible.

[MetalAlien]

Oh the horror show! Talk about a scarey thing to happen... I know I would have freaked out! good luck, I hope someone on here can help you.

[Enigma]

I have never had this happen on my ATV but I have had bolts break off deep inside the hole where you cant get at them.

I ended up taking them to a small welding/fabrication shop I do biz with. They got it out. Might be worth talking to them if you know of a reputable outfit.

[Jim]

Make your own easy out you have a center to go off of clutch or not ..reverse grind it 4 corners 5*angle...or cut it off we sell clutches,,Why do we run two crank keys to run a blower at 30 psi..,yes you will see keyed clutches here before long they are galling with 100hp and up ask any engine builder ...sorry for your problem and a viable reply ...I understand your plight sir...sorry..it will come out take your time and think....JH