Snapped Radiator Bolt.

I spent this afternoon replacing my spark plugs after doing the rear plug i moved onto the front plug.

The bolt for moving the radiator at the bottom of the rad was pretty stiff and instead of breaking free it snapped , can anyone give me some advice on drill this out.

What size of drill bit do I need and what bolt do I require to replace it with.

Is it possible to use a bolt and nut combo on this one?

Total nub here.

When it come to drilling start as small as you can and increase it 1mm at a time till you get your desired diameter . DO NOT just get a 5mm or 6mm and plough straight in . It may take a little longer starting small but you get a much more accurate hole as a result.
As for securing the rad , if there is space and access on the other side of where the bolt goes into then just go right through and nut and bolt it . For added peace of mind put a longer bolt in and use two nuts to tighten it in place . It will never come free unless you want it too . Also use some grease on the bolt before you put the nut(s) on .
Hope this helps .

Your finished hole diameter is dictated by the size of holes that need secured and the size of your available fastenings . Try not to go smaller than M6 (6mm) if possible with your finished hole .

Makes you wonder how long ago the front plug was changed if the bolt was that corroded. Shame you didn't drench the bolt in WD40 or similar whilst you dealt with the rear plug. Ah well, live and learn, but I would treat every other bolt with kid gloves and suspicion.

Good luck with the repair

Originally Posted by xbox650

When it come to drilling start as small as you can and increase it 1mm at a time till you get your desired diameter . DO NOT just get a 5mm or 6mm and plough straight in . It may take a little longer starting small but you get a much more accurate hole as a result.
As for securing the rad , if there is space and access on the other side of where the bolt goes into then just go right through and nut and bolt it . For added peace of mind put a longer bolt in and use two nuts to tighten it in place . It will never come free unless you want it too . Also use some grease on the bolt before you put the nut(s) on .
Hope this helps .

+1 and use stainless if possible for the replacement nut & bolt.

I only got the bike about 4-5 weeks ago upon doing my first service the bolt which holds the seat down was chewed to bits which led to me having to take it to a mechanic to have it removed.

This is the second seized bolt sadly this one snapped.

The radiator is currently being held by the top bolts and the fairing lowers which are completely to pot as the rad is in the wrong place.

[yorkie_chris]

It'll be fine being held by th top bolts and fairing for the moment.

If you can accurately center punch it then chances are it'll spin out once you drill through with a smaller drill, if not then its easy to use a nut and bolt rather than a tapped hole.

It's no big deal, not a critical one to bodge.