I did a search and saw some ideas for different bolts, but wanted to be sure about this specific application. Recently bought a used 900RR (99) and saw it was missing the right side frame slider. The bike had minimum scratches, so wasn't sure why it was missing.(seller didn't know either, he was 2nd owner) Well, it looks like the slider bolt broke off in the engine mount hole. The frame and engine holes now seem that they may be misaligning. I definitely don't want to mess with the bolts that hold the engine in, I know they're there for a reason. Anyway, I attached some pics. I looked at the left side and saw the bolt went right through to the the back of the engine mount (I could see it sticking out the back, so assume it's a hollow hole ). Any suggestions on how to get out the broken piece? I was thinking an EZ out, or Grabit (thanks Chainstretcher). But want to be sure not to mess with the aluminium engine mount hole. Frame slider/bolt replacement suggestions? I read it should be a mild bolt, but not hardened. Any help would be truly appreciated. Sorry if this was already asked, but couldn't find it.
PS. Thanks Cuipe for your answer to my brake/caliper question, you guys are great!

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More pics

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one more pic

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sorry, I'm new

 

No ideas? I was just thinking of retapping and installing a new frame slider with bolt. Can I use a regular tap for the engine mount? Thanks

 

An easy out might do it, but I'd be more concerned about the mis alignment on the engine to the frame. The other side and other mounts are doing all the work and that's quite a little gap there between the two. Once you get a new bolt in there, it will most likely true everything up again. Might want to loosen all other mounts though so this particular hole doesn't get stressed and strip the threads right out of the hole from trying to 'force' it back into alignment. If you get new sliders that fit the same area, they'll come with the bolts needed. If not, definately go to the dealer and get an OEM bolt for that mount.

 

Loosen the other engine mount bolts and support the engine with a floor jack. Jack the engine up so that the hole lines up. If the easy-out doesn't get it, then just drill the bolt out starting with a small drill bit (1/8" or smaller), making sure that it's centered (recommend a center punch), and then work your way up the drill bit sizes incrementally once the hole is big enough, you may be able to twist the remaining threads out of the hole. If not, you can use a punch to fully remove the threads. Then retap the hole, or if needed, go one size up on the bolts.

 

Well, I got it. Went to Sears and bought all new taps, easy-outs, and titanium drill bits. What was the biggest headache was trying to do this by just removing the fairings. I tried at first to drill real tiny holes, but even after using a punch, I could never quite get the center of the bolt. So I ended up using a bit just a little smaller than the replacement bolt, so there would be little room to miss the center(just as a starting point). After using that, I used something like a 9/32 and that did it. Since I gave it a shot of PB blaster an hour before I started, after the drill got inside enough, it just grabbed the bolt and screwed it in, which went right through to the back, falling out. It didn't even hurt the existing thread. So now I've got some new tools, but I really only needed the drill bits. (BTW, drilled on slow setting, using cutting oil and compressed air( to clean out the shavings) every minute or so. Here's some pictures of the culprit.

PS. I found out here in Vegas that close to no dealers or shops stock many bolts/sliders for the 900RR. Everyplace I went, they said, "oh, we have to order that" Kind of a pain. Anyone else find that problem?

Thanks zerochickenstrips and dwhite645 for the advice!

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