Get a 1/4"-20 tap. Drill the broken screw out and run the tap through. Should be OK.

 

very , very wise , use a large number of towels, cover everything..not to funny when a wrench,bolt screwdriver, tool, or beer slips and dents the fender or tank.

what ever method you use to extract this screw make damn sure you cover fender and tank with
a towel ,quilt or something because it may turn into a fender or tank repair as well
just a precaution when working in really close to painted parts.

 

Those lower tree's with the exact holes your using are not covered with plugs during the powder coating at the factory. This causes powder coating to fill the treads and be rather nasty after its been baked.....

I've added the lower air deflector and chased the holes out with a chase tap and broke the tap, I know how your feeling right now. My only consilation was the tap was out just enough to get a bite on it with vise grips and work it till the hole was clean enough to back it back out again.

At best with good tools (proper) it may be dicey getting out the broken bolt. You may end up just drilling it and then having to have it heli-coiled with new threads in the worst case scenerio.

IMO get someone to look at it before trying to scratch up or chip any paint doing it yourself. Chances are that you can get a machine shop to remove it with out having to put in a heil-coil!

Good luck with it.

 

If enough of the screw/bolt is protruding out so you can get a grip on the screw then use a good pair of vise grips. If not, then look on the inside of the lower triple tree, the screw should be sticking through so you could use a pair of needle nose or small set of vise grips to remove it or screw it backwards so you could then get a good grip using vise grips.

If not then you will need a 1/8 drill bit and a no. 1 screw extractor. You will need to center punch the screw so the drip bit will not crawl. Make darn sure you drill straight or you may damage the threads. If you do damage the thread then you can fix them using a 1/4-20 Tap.

And like the man said, cover your paint or you may be sorry.

Good Luck!

 

You could try to cut a slot in the top of the bolt that is still sticking out, with a dremel tool and then use a flathead screwdriver in that slot to "unscrew" it or back it out. I did this on a torx head bolt that stripped out and it worked pretty good.