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What did you do to Your Sportster Today?

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  #5261  
Old 04-02-2017, 04:52 PM
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Originally Posted by hscic
I know there are a lot of experienced wrenchers on here....what is the best way to get off an rounded/stripped allen head bolt off the primary cover?
Try cutting a slot in it with a dremel and cutting disc. Do it deep and big the first time use the largest screw driver possible.
 
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  #5262  
Old 04-02-2017, 07:02 PM
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Went on my second ride today. The first ride was about 20 or so miles as it was the first time I had ridden in almost 11 years after my wreck. Today my Son-in-Law and I did about 125 miles. Did a little of everything. Back roads, hi-way, through towns. Just a nice ride! Still a little rusty but the nerves were fine!
 
  #5263  
Old 04-02-2017, 07:12 PM
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I installed a used Daymaker headlight, a set of detachable saddlebags and a rear light bar off a touring bike..

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  #5264  
Old 04-02-2017, 07:29 PM
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Originally Posted by Lonnie Mac
If all else fails, then the No1 thing I always turn to is a left hand drill bit set. 99% of the time the screw will come out soon after you start drilling.
I've done the Dremel thing a couple times myself, on smaller screws. I hate extracting damaged/broken stuff.
 
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  #5265  
Old 04-02-2017, 07:47 PM
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Originally Posted by Lonnie Mac
Anything at all left whatsoever? If so, a good impact driver will save your butt many times over! Get you an impact driver, and some good impact allen's. You will love it. Most indy shops in our area, including me, don't even try with a wrench first . Just go straight for the driver to break them free.


Yeah I have an impact driver but used a wrench first (my mistake)...yup should have gone straight to the impact first. I tried to use a size up torq bit and tapped it in for a tight fit....then used an impact driver but it tore away whatever was there. arg.
 

Last edited by hscic; 04-02-2017 at 08:00 PM.
  #5266  
Old 04-02-2017, 07:47 PM
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Originally Posted by Billy W
Went on my second ride today. The first ride was about 20 or so miles as it was the first time I had ridden in almost 11 years after my wreck. Today my Son-in-Law and I did about 125 miles. Did a little of everything. Back roads, hi-way, through towns. Just a nice ride! Still a little rusty but the nerves were fine!
Awesome! Glad you're back out there.
 
  #5267  
Old 04-02-2017, 07:56 PM
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Originally Posted by WKNDS
If there's nothing for a 'bit' to grab, then use an easy-out extractor...

Looks similar to this:
Thanks for the suggestion...yes nothing to grab. I have a set of those and a set of extractors that grab outside of the bolt/screw head, but afraid to use them on the primary cover and end up at a point of no return...lol. Perhaps cutting a slot in the head may work.
 
  #5268  
Old 04-02-2017, 08:06 PM
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How many are bad?

If you dremel (grind) or drill the head off then the cover will slide off the bolt after removing the other good bolts and you'll have a lot to grab on to
 
  #5269  
Old 04-02-2017, 08:18 PM
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Originally Posted by multihdrdr
How many are bad?

If you dremel (grind) or drill the head off then the cover will slide off the bolt after removing the other good bolts and you'll have a lot to grab on to
Thanks...I thought of that. So I bought the show polished grade 8 engine kit from Alloy Boltz, Inc and will probably change them all out.
 
  #5270  
Old 04-02-2017, 08:36 PM
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i have taken a star/torx bit that was one size bigger. gave it a few taps with a hammer to get it seated. thats taken gotten the rounded allen bolt out
 


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