Buddy of mine just paid too much money to a shop to do carb cleaning. Hmm...the thing did not run right. I told him I would look into it, as he was about to leave for a two week trip and was leaving the bike home. 1986 Intruder 700. He parked it in my garage, I asked him when was the last time the valves were done, and it was at least 15k miles ago. So, I told him I would do his valves, oil change, air filter changes, synch his carbs...whatever should be done. Both his exhaust/cylinder and coupler gaskets were gone, plus the mid connector pipe had no clamp. I told him I'll look at it. Took the exhausts off (struggle - seized bolts). Replaced gaskets, fixed the mid pipe, put on a clamp...so far so good. The I started taking the chrome covers off to get to the valve covers. First bolt came out after some struggle. Second came out with some aluminum threads on it (was overtorqued). I started being more careful. Third bolt (front cylinder, right) I took my open-end wrench, pulled a little, and the bolt snapped. The last one came out okay. So, I had a broken bolt that broke without any effort. It was broken flat with the cylinder fin. I sprayed in some PB blaster, let sit overnight. No room for a good drill to get there, so I took a flexible shaft, drilled a 7/64 hole just deep enough, tapped in screw extractor (spiral), gave a little spin and the sucker broke inside. I tried taking it out with a diamond coated dremmel bit. and just got a little dimple (no room for the dremmel to be straight) Took it to a car shop today. We tried welding a nut on it. The easy out came out with the first weld. We welded up the broke bolt, welded a nut on top of that. Five times in a row the sucker broke off. The nuts were red hot from the welding, and it still did not move. But all this heating started to make the aluminum melt around the welds, (just a teeny bit), so I told the shop to stop. The easy out is out, but now the broken bolt has hardened by all the welding. Drill bit just slips on it. I'm ready to sacrifice the threads and just helicoil it afterwards, but I can't get the bolt out. Heat, PB Blaster, welding, tapping - nothing moves it. This is the bolt 6mm for the decorative covers, so nothing structural. What can be done? Oh, after this experience, I decided not to do the valves. The 6mm valve cocer bolts did not move even with 20ft/lb force, and I'm not comfortable applying any more as i'm afraid they, too, will snap. then the engine would have to come out. Whoever worked on this bike before really overtorqued stuff, and probably used some sealant. I tried doing his forks as well, and the bolts in the clamps don't move at all. Also, the shop where he took it for the carbs charged him for new plugs, but they were not replaced. The carb to carb cable is all messed up, and adjusting screws have stripped threads. Sorry, I guess I'm asking a question and venting at the same time.