Rear brake caliper
 

1990 xt 600. Snapped one of the chrome bolts going into the caliper. I was wondering how hard to is it going to drill that out, ez out whatever to install a new bolt. I am going to order a new bolt. One good thing is the bolt snapped sticking out and the caliper is secure until I see what I can do

Ae you traveling or home?

If on the road find welder to weld something to sticking bolt if here's enough material and then get it out. Heating cycle will help to loosen it up. Most of auto repair or muffler shops can be of help.

If this is not feasible and you want to DIY order an extraction kit but also heat treat it and/or soak in some penetration oil (atf/diesel would work in a pinch too).

I am home. But I have a 1/4 inch or a little less sticking out. Waiting on the bolt to come in before I do anything. But for now the broken bolt is holding the caliper from moving

Not sure if it is possible on the 600 caliper, but if you remove the wheel and the other caliper bolt, can you rotate the caliper enough to slide it off the broken bolt? This will give you more of the stub to get a grip on.
Definitely use heat to break the grip - ally expands faster than steel, but don't get too enthusiastic with the oxyacetylene - it melts without warning too!

shouldnt be hard, but that "depends" as they say....


did you snap it while trying to unscrew it due to it being frozen?


or it snapped while torquing it down due to over torquing it?


And what is your skill level?



if heavily frozen/corroded in place and you are afraid of damaging it, remove the whole caliper and take it to a shop.



put some copper paste on bolts when putting it all back together so it doesnt freeze next time

I have started to use my local thread guy...Threadworx. saves any messing about. He'll do repairs in situ or not. Possibly someone with similar skills near you...

Cheers
Min