How to unscrew stripped tight clutch bolts?

[geluso]

hello! I got a 1985ish 650 recently. The clutch feels weak. I want to replace the clutch rings. The Phillips head bolts inside the clutch are stripped and tightened.

any tips how to undo these stripped bolts, or how to remove the clutch entirely?

https://imgur.com/a/J1TniwE

 

[Wingedwheel]

Got a hand impact?

 

[gggGary]

Yes getting those pesky often stripped out bolts out is the next step. They are #3 JIS tho #3 phillips bit will do. NOT the standard #2 bit.
Starting with least destructive; solidly tap, hammer in a #3 phillips bit. Then use a battery or hand impact wrench.
Alternate loosen tighten directions, that will "break loose" the bolt (nothing more satisfying to hear than the crick sound when the bolt finally unsticks) then it comes out.
When that fails, try a center punch and push the corners towards the center of the head to "reform" the phillips slot.

not yet? put a cut off wheel in a dremel and make a nice neat straight slot for a large straight impact bit, repeat above.
No joy? drill off the heads, the plate will now come off and a vice grips will easily remove the screws.
MikesXS sells replacements.
https://www.mikesxs.net/yamaha-xs65...?fits-motorcycle=Yamaha/XS650/all-models/1977
OEM Yamaha also.
https://www.partzilla.com/product/yamaha/90149-06102-00?ref=64f7dfc69190cbd627d1a7d1230a4e5c0c7ccdf6

 

[Its been a long time]

When you put it back together again, I would think about using these instead of the cross head screws (link below). The kit comes with stainless screws and I used the regular black screws as I'm not a fan of stainless steel inside engines. They're available elsewhere not just Yambits.

https://yambits.co.uk/xs650-clutch-spring-bolt-kit-p-43434.html

 

[JJames]

'85?

 

[geluso]

'85?

Yes, that's what I remember being told. What do you think? Is 1985 a valid year?

If you think this is another year I'd love to know whatever you're thinking to save me headache down the road. Thanks!

 

[geluso]

Yes getting those pesky often stripped out bolts out is the next step. They are #3 JIS tho #3 phillips bit will do. NOT the standard #2 bit.
Starting with least destructive; solidly tap, hammer in a #3 phillips bit. Then use a battery or hand impact wrench.
Alternate loosen tighten directions, that will "break loose" the bolt (nothing more satisfying to hear than the crick sound when the bolt finally unsticks) then it comes out.
When that fails, try a center punch and push the corners towards the center of the head to "reform" the phillips slot.
View attachment 370131
not yet? put a cut off wheel in a dremel and make a nice neat straight slot for a large straight impact bit, repeat above.
No joy? drill off the heads, the plate will now come off and a vice grips will easily remove the screws.
MikesXS sells replacements.
https://www.mikesxs.net/yamaha-xs65...?fits-motorcycle=Yamaha/XS650/all-models/1977
OEM Yamaha also.
https://www.partzilla.com/product/yamaha/90149-06102-00?ref=64f7dfc69190cbd627d1a7d1230a4e5c0c7ccdf6

Phenomenal. Thank you!

 

[nj1639]

Yes, that's what I remember being told. What do you think? Is 1985 a valid year?

If you think this is another year I'd love to know whatever you're thinking to save me headache down the road. Thanks!

1983 Heritage Special xs650 sk. Multi spoke wheels, “650” emblem on the chrome cam end covers, tin top bs34 carbs.
Last year of the xs650’s sold in the states.

 

[GLJ]

Look up your vin # Lot of very good information in the Tech section.
https://www.xs650.com/threads/xs650...-other-information-including-xs750-850.30569/

 

[jetmechmarty]

The factory painted the engine cases black in 1982 and 1983. You might have a mix of models cobbled together. Not that there’s anything wrong with that! We can help figure it out as necessary.

 

[jetmechmarty]

P.S. I believe I see six friction plates which indicates a 1982 or 1983 clutch IAW the FSM.

 

[geluso]

Good news! My friend came over with a square-drive phillips head bit and was able to zip these bolts off without any problem. It was a huge win for the day.

I bought the replacement bolts that have hex heads so I'm happy to have those on now. I replaced the clutch friction discs and the bike is up running well now. Now it is time to tune the carbs.

Thanks for the advice everyone.