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Discussion Starter #1
Snapped the long bolt while replacing the cover over the oil filter on a 2006
Burgman 400. Any suggestions on how to fix this problem?
 

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It depends on where it broke. If the head snapped off and you can get to the remainder of the bolt you might be able to get hold of it with a small set of needle nose pliers and screw it out. If you decide to try to use something like a screw extractor be careful not to damage the magneto cover when drilling. It's pricey to replace at about $200

If it broke off further down where you cannot get to the remains you are going to have to pull the magneto cover off the side of the engine so you can get to it. When you do that the remains of the bolt should just be sticking out where you can get pliers on it. Getting that cover off will require removing the water pump first. You will also need the gaskets and o-rings to put the magneto cover and water pump back on.

http://www.partshark.com/fiche_section_detail.asp
 

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Discussion Starter #5
Buffalo, the bolt did snap pretty far inside. Anyway the hole can be threaded and a smaller bolt screwed in similar to the other two bolts that hold the cover in place?
 

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You could but that bolt does double duty as one of the bolts that secures the magneto cover. It might develop a leak at that point on the cover.
 
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