Motorcycle Repair: broken bolt, 1981 honda cb650, quality rust

Question
Falcon,
I was recently given a 1981 Honda CB650, that has been sitting in a Tuff shed for about 8 years.  When i got the bike to my garage I found the fuel tank to be full of gas and the engine covered in oil, so I knew I needed to clean the fuel system.  At the same time I thought I would change the head and base gasket and put an end to the oil leak, not knowing much about engine work I knew this project would be a learning expieriance.  I bought an instruction book (Haynes) and got to work, here's the problem, your probably familiar with the 22 bolts that hold the cylindar head cover.  Well I broke one, I'm only about 20 mins. into this project and I'v run into my first problem whats the best way to remove this broken bolt?  Do you have any hints or tips I should know as I continue to pull apart this engine?
Thanks,
     Brian

Answer
Hi Brian.
 You have a couple of options here, depending on how much of the bolt is exposed.

1)  If enough of the bolt is exposed and you have the room to maneuver a pair of good visegrips, then you grab the bolt by the shaft with the visegrips and try to turn it out while tapping the bolt with a hammer till it loosens up and moves easily.  Make sure that you use a top quality rust breaker on the bolt as well.

2)  If the bolt is not exposed enough, then drill out a small hole down the bolt's centerline and use a bolt extractor on it.  If this does not work, then you may need to rethread the hole.

3)  If the bolt is not exposed enough and refuses to come out with a bolt extractor, then drill it out completely and rethread the hole.  This requires a new bolt in a slightly larger size and a tap and die in the size of the new bolt hole.

The problem with bolts is that if they don't want to come out, it normally leaves you few options.

Good luck.
FALCON