Topic: How F'd am I? (Broken Clutch cover bolt)

[DJBlackRabbit]

I have one bolt left to take off my clutch cover on my cb550 and it wouldnt come off (bad angle with tools i had). I tried a manual impact, my JIS drivers, a powered impact , cutting a slot with a Dremel then powered impact again, then I tried drilling it out with a reverse bit all to no avail. The hole drilled is off center (my dumbass fault) and it looks hopeless. Any thoughts on getting this cover off?

[exponent]

Deep breath

Drill again

Deep breath

Heat with torch

pb blaster

Extractor

[Alan F.]

Drill the head off as best you can and try not to damage the cover. If you damage the cover patch with JB Weld, at least it's at the top where it won't leak much. Check often while drilling so you don't go too far.

Don't worry, you're not the first and won't be the last.

[scottly]

That's not bad, just switch to a 1/4" drill bit, and drill the head of the screw off. Pull the cover off over the stub, and use vise grips to unscrew it. When drilling, try to redirect the point of the bit to the center of the screw shank, then push the bit straight in, if that makes sense..

[Alan F.]

Also be aware that the stump of the remaining screw will have sharp edges.

[Don R]

 What Scottly said. It works.

[DaveBarbier]

+1 to scottly

Not a problem yet. Get the cover off and deal with the remaining stud. Heat (propane) and vise grips.

[dave500]

with a sharp chisel or pin punch you should be able to knock that in the undo direction with care,ive done plenty of the same,at least give it a shot,once its nudged itll come out with vice grips if you can get a decent grab on it,also try hitting it straight in with a straight square punch,might shake up the stubbon threads?

[Kelly E]

Most of the time once you drill off the head and remove the cover the shank of the bolt will probably unscrew by hand.

[dave500]

funny how old jap road bikes had those JIS heads but the dirt bikes got allens?

[2wheels]

I like Scotty's way.
Once the case is off and the vise grips are on.  Be very very careful.  Remember you have hours to get the screw out,  No Hurry.
Back and forth, back and forth on that screw.  Do NOT rush.  Add lots of penetrating oil.
Propane torch heat is very helpful.

The threads of the screw are probably full of that nasty white corrosion.  It will wash out with the back and forth action.

[DJBlackRabbit]

That's not bad, just switch to a 1/4" drill bit, and drill the head of the screw off. Pull the cover off over the stub, and use vise grips to unscrew it. When drilling, try to redirect the point of the bit to the center of the screw shank, then push the bit straight in, if that makes sense..

A lot of good info here guys! Thank you will try again today

[MrGardman]

I remember removing the head and cylinder studs from 750s. Some were terrible to get out. A little heat will do wonders for that white corrosion.

[Gurp]

My first move would be slot it deeply with a dremel then use a hand impact driver and a good hammer. taken many out that way.

[Ellz10]

That's not bad, just switch to a 1/4" drill bit, and drill the head of the screw off. Pull the cover off over the stub, and use vise grips to unscrew it. When drilling, try to redirect the point of the bit to the center of the screw shank, then push the bit straight in, if that makes sense..

A lot of good info here guys! Thank you will try again today

Slot it, torch it 1-3 mins, cold chisel. Rinse & repeat.

I've been there so many times before and I'm sure many more times to come.

You'll figure it out.

[desertrefugee]

... and nothing [NOTHING!] is more satisfying than that "pop" when a stuck screw releases and comes free!

[jgger]

A trick I learned a long time ago, before you get to the "drill phase" of oh crap screw removal. On the boogered head use a flat punch to peen the boogers part back into the screw,just a little more than making the screwdriver fit. Then use the bit from your impact driver and tap it into the hole for a good tight fit. Then use the impact driver with a larger than normal hammer for that one last hail Mary whack, don't be shy. This works about 90% of the time and has saved my butt more times than I  care to remember. If it fails you still have the drill.

[desertrefugee]

Hmm.  I have honestly never tried that, but I could see where it might work. Noted and filed away. Thanks!  Never too late to teach an old dog new tricks.

[Bankerdanny]

That's not bad, just switch to a 1/4" drill bit, and drill the head of the screw off. Pull the cover off over the stub, and use vise grips to unscrew it. When drilling, try to redirect the point of the bit to the center of the screw shank, then push the bit straight in, if that makes sense..

I had to do this with 3 screws on my valve cover, it works like a charm.

[craz1]

If the head is exposed and you can get a vise grip on the side of it and twist it, that normally works. Otherwise drill the cap off and deal with the stud.

[DJBlackRabbit]

Deep breath

Drill again

Deep breath

Heat with torch

pb blaster

Extractor

def needed to breathe lol! Thanks everyone for the advice! Cutting the head off and smacking/pulling the cover eventually worked. Had the same issue with the stator cover and used the same method!!! Grateful

[Kevnz]

Good news. Hopefully plain sailing from here.

[dave500]

even with a good impact driver and correct JIS bit you should dig the cross slots out with a scriber or similar,then with compressed air blow them out,then insert just the bit only and hit it with a decent hammer to hopefully loosen the threads,then use the impact driver,lotta those screws aint been out since the factory install!