How Do I Remove a Broken Honda ATV Cylinder Bolt?

It’s every ATV mechanic’s nightmare: a stubborn bolt that won’t come out and then breaks off, turning a short repair job into an incredibly long repair job!  

Partzilla’s Honda ATV expert John Talley hosts live Q&A sessions on our YouTube channel every Friday at 3pm Eastern. In this session, John was asked for his advice on how to remove a broken cylinder bolt from a 2003 Honda Rancher 350. 

Broken Honda Rancher 350 Cylinder Bolt Q&A

I have an 03 Honda Rancher 350 and the long 10mm bolt that holds one side of the cylinder broke off flush. Any tips to get it out?

John Talley: Yeah, I do. It's from a different part of the engine, but we just published a video on our YouTube channel in which I snapped off a head stud on our 2016 Yamaha YXZ1000R, and the process I had to go through to try to get it out. I ended up having to drill it out and then Time Sert it, so I would bet that same procedure would apply to your particular situation. It’s not a lot of fun to do, so take your time, maybe follow my example and I can guide you through it. Isn’t that aggravating? Every project is just one broken bolt, or I should say every three-hour project is just one broken bolt from turning into three days. It happens to us all eventually when we work on these things long enough. 

Watch the video below to see how to remove a broken exhaust stud bolt from a cylinder head. 

Watch the video below for tips on how to remove a stubborn broken bolt that won’t come off.

Watch the video below to learn about the differences between Time Sert and Heli-Coil thread repair tools.

Want to see more live repair questions answered? See more motorcycle and ATV repair questions answered here.