I assume you are using " Standard Mesh". Try with "Curvature based Mesh".
I think your issue does not necessarily lie with the bolt connector itself but with whatever contact is defined at the interface of the two bodies being bolted together. Your description doesn't mention anything about creating "No Penetration" contact sets. Have you created that No Penetration contact sets that work in tandem with the bolt connectors?
This message may pop up when running an analysis containing either connectors, remote loads, cyclic symmetry or elastic support, one of which has a problem. Depending on the version of the product and the connector, remote load, cyclic symmetry or elastic support causing the problem, the exact wording of the error message may vary.
Source surface not defined at Remote load XXX
Source surface not defined at Pin connector XXX
Target surface not defined at Rigid Connector XXX
Target surface not defined for Spring Connector XXX
The program detected a problem with the definition of the connector, remote load, cyclic symmetry or elastic support.
When you get this error message, you should review the definition of the connector, remote load, cyclic symmetry or elastic support mentioned in the error. Typically, the number mentioned after the connector, remote load, cyclic symmetry or elastic support is its internal ID. The Id of any item can be found by right clicking on it and selecting Details. You can use the pin on the Details dialog box to keep it open while you browse through all the items in your study.
When you have identified the faulty item, edit it and review its definition. Chances are that the definition is invalid.
Make sure the required selection fields are not empty or populated with incorrect geometric entities
Check the mesh in the vicinity of the bolt entity to make sure it is adequately refined. Oftentimes a mesh that is too coarse can cause this error. Applying mesh controls and/or adjusting the tolerance may solve the issue.
For bolt connectors: Check the contacts defined between the components that the bolt connector is joining together. There should be distinct no penetration contact sets between each contacting surface, and these should not conflict with any other contacts defined in the area.
If you can't identify the connector, remote load, cyclic symmetry or elastic support causing the error, a good general approach to narrow down the problem might be to suppress components, loads connectors and fixtures as much as possible to simplify the model, and then add them back gradually until the problem shows.
Thanks for all the feedback, I appreciate it and if I get this message again I will refer back to this post.
However, I wish you guys had replied last year when I was having this issue. It's been so long now I don't even know what file I was working on that this message is in reference too. ha-ha
Woops!. I just saw that it was bumped by a comment.