stripped head on clutch cover bolt

[RobertGS]

So with an impact driver I somehow managed to strip one head on the final bolt I was removing from the clutch cover.

Read a bit and decided to chisel a notch for a flat head. Have applied penetrating oil twice... wiggled with a flat head.

Now before I hit this with the impact screwdriver again, this time with a flat head, any other ideas? I really want this thing out without any more excitement.

[rustybronco]

Vice/mole grips.

[tkent02]

Failing the impact or the Vice Grips, drill it until the head pops off, remove the cover and then pull it out. But the impact should work.

[Guest]

I would just drill it off, just go far enough when the head pops off. Had to do that to a friends clutch cover, he stripped out every screw. Just took a bit that was about the same size as the head and drilled it until the head just pretty much fell off. 12 times, not one mess up. Once the cover is off, take a pair of vice grips to the remaining stud and screw it out. Should be easy since there is no pressure on the screw then.

[Crankthat]

Try tightening the other bolts again and then try to take this one out.
It may take some of the pressure off this one.

[GSX1000E]

Now before I hit this with the impact screwdriver again, this time with a flat head, any other ideas? I really want this thing out without any more excitement.

Cut the slot almost flush with the cover and when you hit the impact use a REAL hammer like a 3-4 pound baby sledge and REALLY MEAN IT! You have one try to not screw it up worse.

[RobertGS]

Thanks everyone for the quick response.

Tried the vice grips, no go.

Then drilled the head off removed the cover and bingo, the remaining bolt screwed out by hand.

Thanks all and Bill for the drill tip.

Now go to clutch forum in a bit for a scary video (If I can figure out posting it quick) on how loose the center shaft is... Wow.

[srg]

I'm surprised no one mentioned this yet: HEAT!

It works better than you'd think!

You can always heat up a screw-driver bit on the stove, then hold it on the screw head for 30 seconds or so. Or, if you DO have a torch/lighter, use that to heat up the screw a bit.

PB Blaster is flammable, so wipe it down before you heat it up. It might smoke a bit, but it's fine as long as there's not a puddle of it.

[Guest]

I'm surprised no one mentioned this yet: HEAT!

It works better than you'd think!

You can always heat up a screw-driver bit on the stove, then hold it on the screw head for 30 seconds or so. Or, if you DO have a torch/lighter, use that to heat up the screw a bit.

PB Blaster is flammable, so wipe it down before you heat it up. It might smoke a bit, but it's fine as long as there's not a puddle of it.

No need for heat with this application. It's not that big of a deal.

[RobertGS]

Yes I may have hid the big outcome below, but it's all done. Drilled the head off which them allowed the cover to come right off leaving the stud to easily come out. Great advice all, thanks.

[chuck hahn]

Or you could have also dremeled a fat slot in it and used the flat bit in the impact driver kit.

[RobertGS]

Yah I gave that a try Chuck. Probably just lousy first effort, but I couldn't seem to get the slot right. Both the screwdriver and impact driver kept wanting to jump out.

So I went the other route. I imagine that I should get better at that "cut the slot" method since the next time it's probably going to be a bolt that is threaded immediately into the bike rather than way the clutch cover is bolted.

[chuck hahn]

Cut them deep and wide so the bit fits way down in there for the best griping power. And dont be afraid to give it a good heavy sharp smack. Dont knock the bike over or shatter anything..but you get the point.

[blowerbike]

i can get any of them out with a chisel/punch and hammer...hit the head at an angle and the screw will spin free...been doing it since the british bike days.