Mother of all that is holy! Stripped Allen head...

Jpwhit1 · Mar 30, 2015

Apparently the screws are made of adamantium!

The carnage..

Devil spawn..

There is part of an extractor broken off in the middle. You cant see it because the evilness has made it apart of its hoard of hardness.

It's eating drill bits like crazy. Ideas?

fredintoon · Mar 30, 2015

Hi jpw,
"easyout" eh? Their very name is a black lie. Two ways I can suggest to get that disastered stub out of there.
DIY method is a diamond grit grinding bob in a Dremel tool.
Pay a professional scads of cash method is to pull the motor, strip it down as much as it can be with that case in place and get the thing burned out with an EDM (Electrical Discharge Machine)

tonyc · Mar 30, 2015

Remove the remaining bolts and take the cover off. There will be enough to grip and remove.

angus67 · Mar 30, 2015

tonyc said:
Remove the remaining bolts and take the cover off. There will be enough to grip and remove.

yes. keep drilling the evil one until the head is all gone, then take the other bolts out, and take off cover.
and use oil. any oil.

mjpchief · Mar 30, 2015

See if you can find a left hand carbide bit and try drilling down the center of the screw. If that doesn't work you might find a welder that can weld a rod to the stripped bolt head. Let it COOL TO ROOM TEMP and it may turn out. If none of this works and your particular about the looks of the case buy another case and bust this one off and take the screw out with vice grips. That case looks screwed anyway. Soak it with Kroil if you have any.

Posted via Mobile

pamcopete · Mar 30, 2015

tonyc said:
Remove the remaining bolts and take the cover off. There will be enough to grip and remove.

jayel · Mar 30, 2015

that mess is from him trying to drill the broken off EZ out, (harden steel) agree with taking the side case off

hard_y_rd · Mar 30, 2015

If you broke an easy out in there alli have to say is good luck. I broke a drill bit out in a clutch bolt trying to do the clutch mod and there is no way to drill that thing out. I'm sure an easy out is harder than a drill bit.

Joe Smith · Mar 30, 2015

If you need another clutch cover I have a few and could send you one on the cheap.

HooliganCycles · Mar 30, 2015

If you get really desperate I'm in coos bay and can get it out for you if you wanna drag it over here

TwoManyXS1Bs · Mar 30, 2015

I'm thinkin', out of desperation, could do multiple 'quick shots' with a mig, and build up the head's surface, all the way out to clear the case. You'd want to have a protective cover over that, with a hole positioned over the bolthead...

angus67 · Mar 30, 2015

TwoManyXS1Bs said:
I'm thinkin', out of desperation, could do multiple 'quick shots' with a mig, and build up the head's surface, all the way out to clear the case. You'd want to have a protective cover over that, with a hole positioned over the bolthead...

and then grind flats on it so u can get it with a wrench.

wherearewe · Mar 30, 2015

Faarrrrrrrrkkkkkkk... I reckon write the cover off.... First just get it off over the remains of the bolt and EZ out. Then use Twomany and Angus idea. Perhaps weld a bolt head on and turn.

angus67 · Mar 30, 2015

wherearewe said:
Faarrrrrrrrkkkkkkk... I reckon write the cover off.... First just get it off over the remains of the bolt and EZ out. Then use Twomany and Angus idea. Perhaps weld a bolt head on and turn.

so you can weld? Weld a nut on it. the heat from welding should break it free, then with a nut on the end of it, a wrench should get it.
I am optimistic this will work.

Jpwhit1 · Mar 30, 2015

JoE Smith above, had a couple covers laying around and agreed to sell me one. Thanks Joe! Just in case I need it... Updates to follow on Grindgate tomorrow.

barncat · Mar 31, 2015

you could try slotting the socket head with a Dremel with a small cutoff wheel in a 10 oclock-4oclock orientation, then using an impact driver with straight blade. will leave marks on cover but your side cover is somewhat damaged already, but it could be repaired. otherwise i second the above suggestions for welding, which will easily break bolt free with all that heat (use caution if motor still on bike, gas etc..). grinding the head off with that extractor stuck there will be tough... you'll never drill it out at this point.

TwoManyXS1Bs · Mar 31, 2015

I suppose you could try slipping a short steel spacer in there, loose enuff to not bind in the aluminum opening, and it would confine the "mig shots", so as to not damage the aluminum.

I'm sure Angus can do this.

-font-b-Scooter-b-font-font-b-wheel-b-font-font-b-spacer-b-font.jpg

DIRTY DOG · Mar 31, 2015

a small carbide grinding bit in a die gringer or drill untill the head is gone.then slide the cover off, then hope the rest of the bolt comes out of the case ( sorry man ) it is a pain in the but take your time i have done this a few times,

angus67 · Mar 31, 2015

thanks for the props. If you use a nut , just the hole in the nut will keep the sparks contained. Done it twice on bikes with full gas tanks.

Jpwhit1 · Mar 31, 2015

Finally got down to the bottom. Ended up using my Dremel tool and the tungsten metal bit to nip away at the head. I'll have to do some polishing and sanding but I think I can make the cover pretty again. After I removed casing, bolt came out using my fingers, go figure. I started preparing my tools to wrench it out before I even tried.. Thanks for all your tips and advice.

Mother of all that is holy! Stripped Allen head...

XS650 Enthusiast

Fred Hill, S'toon.

XS650 Guru

Welder's penetrate deeper!!

XS650 Enthusiast

Ride.Enjoy.Life is Simple

#9 Guru 74 TX650A

XS650 Guru

XS650 Enthusiast

XS650 Addict

BBQ Hunter

Welder's penetrate deeper!!

Rub on Ya Titties

Welder's penetrate deeper!!

XS650 Enthusiast

XS650 Addict

BBQ Hunter

XS650 Guru

Welder's penetrate deeper!!

XS650 Enthusiast

Similar threads