Originally Posted by
bikerbc
If all else fails and you cant remove it you can use a drill and drill the top off it off just enough so that you remove the bolts head and then when you get the top off the motor there should be enough of the bolt left to grab with the vice grips to remove it .
Yup, this works well. I've done the same thing.
Better still heat the engine body ( not the bolt itself, as this causes it to expand ), then grab the exposed area with the grips and turn slowly to back it out.
If all else fails, you can also use a "center drill" to start a hole into the existing bolt, the follow up with a slightly oversized drill bit. Once you've removed the old material, tap out a new slightly larger thread and use a new corresponding bolt.