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Buell Forum » Old School Buell » Archive through April 02, 2013 » Clutch Cover Torx Bolts « Previous Next »

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Mrpeanut
Posted on Friday, March 22, 2013 - 03:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I was wondering if anyone else had a problem with the clutch cover torx bolts stripping. I liberally applied WD-40 (didn't have any PB blaser on hand that everyone raves about) to loosen them up, got only 1 out of 4 to come free, rest stripped. I'm going to extract them but wanted to know if anyone else had this problem and if so did you just switch hex bolt or put new torx back in. The torx bolts seemed to be pretty weak, very little torque before they were toast
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Mrpeanut
Posted on Friday, March 22, 2013 - 03:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

To clarify I meant the socket head hex bolts, they have a box on mcmaster carr for cheap thats grade 8 and 'ultra corrosion resistant'
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Midnight_rider
Posted on Friday, March 22, 2013 - 06:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

anti seize...alot
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Littlebuggles
Posted on Saturday, March 23, 2013 - 01:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Loosen one, half a turn or so, then the same for the next, and so on. There is back pressure from the spring underneath it, if you undo one too much it tweaks the cover enough to load up the others and they won't come loose.

Take out the one you got loose, find a drill that will match the size, then put it back in (not too tight) and then just drill off the tops of the others. Back out your one good screw and remove the cover. The ones you've drilled will come out with some pliers, possibly, but not likely using vice grips just to start loosening them.

I went with some chromed allen heads from the HD dealership as they corrode less and seem to hold up better than the torx. Many dealers keep these fasteners in stock too, so easy to get replacements if they start showing too much wear.
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Trouble_enabler
Posted on Saturday, March 23, 2013 - 04:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have a 3/8 socket torx set. If one strips, I go to the next size up, tap it in with ball-peen hammer, put the ratchet on it and out it comes. This also works for me on rounded hex head bolts.
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Greg_cifu
Posted on Saturday, March 23, 2013 - 07:22 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Do NOT use an extractor on those screws. If the heads twisted off, so will the extractor and then you'll really be screwed. As others have suggested: drill off the head. After you remove the cover, heat the protruding stud with a propane torch and get it good and hot. That will melt any thread locking compound that might be in there. At that point, Vise Grips should get them off.

Also: do NOT buy the "Ultra corrosion resistant" fasteners from McMaster. They have a very heavy zinc coating that is almost like a layer of paint. The threads are just awful and actually slightly oversize. I bought some for an unrelated project at work and we had to chase every bolt with a die, just to get the nuts onto them.
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Harleyelf
Posted on Sunday, March 24, 2013 - 06:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Use a 45 degree countersink bit to drill the stuck ones out.
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Hootowl
Posted on Sunday, March 24, 2013 - 07:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I used an impact hammer driver thingie. Then I replaced them with black Allen head machine screws.
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Ratbuell
Posted on Sunday, March 24, 2013 - 07:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

+1000 on the heat. Chances are they have threadlocker on them...
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K12pilot
Posted on Sunday, March 24, 2013 - 10:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Heat first always..

I still had to drill one out on my S2.
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Mrpeanut
Posted on Sunday, March 24, 2013 - 10:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks for all your suggestions, I'll be sure to bring a torch tomorrow before going to drill out the head of the bolt. Makes sense that that is why they stripped in the first place. In retrospect it seems stupid not to have thought of it before trying to open it!
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Psykick_machanik
Posted on Wednesday, March 27, 2013 - 11:47 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Heat is the way to go.
If you have access to a heat gun (not a hair drier) id use that over a propane torch. Im just skittish around open flame, flammable liquids, and aluminum. But use what ya got.
If your drilling the heads off use a Left hand drill bit. sometimes you get lucky and they come out while drilling.
Not to be a troll but were you using the right size Torx? the only time ive stripped out a torx is when i used the next size smaller. Just sayin because if thats the case you can tap the correct size into the hole and get a second chance.
Good luck and hope it goes well
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