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There was a time (a long time back ~10 years) when a bolt on my old Kinetic Honda had broken so I had to take it to a welder's who welded a piece of metal rod to the broken bolt and unscrewed it. You may try that.

Nowdays with lot of plastic and rubber parts around bolts, welding is not preferred. They drill a hole along the middle of the bolt and put in another screw and unscrew the broken bolt out.

if your problem is not yet resolved, just post a pic of that bolt.. lets see what the simplest might be..

i could not see the pics so please excuse...

is the bolt stuck / jammed or is it that the bolt has simply had the head sheared when you tightened it?

a sheared head bolt(not jammed) can be removed by making a screwdriver slot on the visible head of the bolt and then simply unscrewing it.

a Jammed bolt has no option but to drill the bolt completely out. you will need to dismantle the part, take to a good workshop, clamp the job on a radial drilling machine and drill through the bolt using a carbide drill. this is expensive and time consuming.

if yu can get the said part for less than 1500 bucks, simply put a new one cos the above process will cost you about 750 bucks and requires a skilled person else you will ruin it.

See these...

Drilling with carbide bits are the simplest. If drilling through out is not possible, you can use a tool called "screw extractor". Costs around 200-300 rupees.
Here's a simple DIY (only if you're competent enough)
How to Remove a Stripped Screw: 8 steps (with pictures) - wikiHow
you can Google for videos too.
P.s. No need to buy tools if you can source or rent it, for around 30mins. Its only a 5 min job.

Thank you all for replying.

I checked with a mechanic in Karol Bagh. He also suggested the drilling option. But for that i would have to dismantle the engine, which i am not ready to do at the moment.

i do have a drill machine with me. Its a 500W normally used for drilling in walls etc. Can i use the normal steel bit for drilling through the stuck bolts? Or i have to go for a titanium or carbide bit.

I did go through a few videos on youtube where they guy first drill a hole and then used a screw extractor. I searched a few shops for screw extractor but they the shopkeepers do not even know about it. On similar lines do we get a reverse drill bit in the market?

@rockrz each bolt is around 4-5 inches in length. and almost an inch long bolt is stuck inside the crank casing.

I was able to open the coil casing as this is held by the bolt head to the crank casing.

I would like to try this myself before taking the plunge of changing the case itself. for which the entire engine will have to be opened.


Any idea how much the cost would for a new crank case?

I am attaching a few images for your reference.

Almost exactly what had happened to me few months ago. One of the the crash guard got broken & the bolt's head got broken & the remaining got stuck in. Took it to a welder. He said, it's a kind of regular for him. Very cautiously he welded another screw onto it & with heat around the broken bolt house, he unscrewed it. Took about half an hour & lot of patience. He was working towards the engine oil pipe & I was really scared. Also, since he was using electric welding machine, it added to my anxiety.

Please post a picture of the broken bolt with coil cover off.
An easy solution is to take the engine to a lathe ,drill the bolt and insert a new brass thread sleeve.
Lathe charges Rs.50 to remove one bolt and Rs.40 to re-thread.

Before welding disconnect the battery and spark plug connector for good