I would get a high quality set of 3/8 drive allen head sockets. I use Snap-on. I also have an impact driver that comes in very handy.

I suspect that your allen wrench is rounded off and that started all this. You should replace all your old allen and torx head wrenches/sockets. If you buy Craftsman or Snap-on, they will replace the bits if they round off.

I was a Cat mechanic for 20 years. Removing broken/rounded bolts is an art in my opinion. There are several good techniques as mentioned above. The trick is to start with the easiest method and progress from there.
1. Try a newallen head socketand impact driver. Buy these tools and I guarantee you will use them in the future. A breaker bar may also help as long as your socket fits well. It may already be too late for that.
2. Avoid heat if you value your paint job.
3. Avoid hammer, chisel and vice grips unless a last resort. If these fail, your only hope is #4.
4. Find a good welder who can weld a nut to the end of the bolt. The heat will also help break the bolt loose. Be sure to protect your bikewith a fire proof blanket and remove your seat.

I believe that half the job of being a good mechanic is having the proper tool to do the job cleanly and quickly. If you aren't going to invest in the tools, leave the work to a mechanic. The beauty of working on a Harley is you don't need a huge variety of tools. Remember, before you use a tool, make sure it is in good shape. Otherwise, take the time to drive to Sears and get a new one. It will save you a lot of grief in the future.

Hope I don't sound too high and mighty. Just wanted to help if possible.
Steve

 

I bought a set of those Sears screw removers. My opinion JUNK. Also WD40 is not a penetrating oil. If the screw head is proud then Vise grips or a good set of Channel locks (used in the correct direction) should do the trick

 

Penetrating oil is for amateures.
My method is to buy any tool that I need. As soon as the allen wrench starts to round the cap screw, drop that and pick up the allen wrench that is stuck in the 3/8" drive scocket. Give the head of the bolt a sharp rap with a hammer. I wouldn't hit it more than once because I don't know if that bracket is cast or forged. By sharp rap I mean, if it were a 16d nail in a new 2x4 it would be driven in about an inch. If you don't know what I'm talking about, quit now.
At the same time call it at least three of the seven things you can't say on TV. Lay over the seat and put you left palm on the wrench over the screw and push hard and call it a miserable f*** while you push down with your right. People constantly under estimate the power of some well place curse words.
Has anyone out there ever seen a screw extractor used sucessfully?

 

This is out of control! Is it a gold plated bolt you are trying to save?

If not, center punch it, drill it out, use an easy-out with penetrating oil on the threads, once removed,chase the threads, install new bolt, get a chrome one, the one in the bike is plated.

Yes, bolt/screw extractors work great if used properly.

 

I don't know that I enjoy removing stubborn bolts but I'm always happy once they're out.

 

For stripped out allen bolts, I'd use my Snap On easy out set. Match the size, insert in stripped out hole and back that bolt out. Easy outs will work, but only use a quality brand. Just don't break the easy out inside the bolt. Would make it harder to drill out again.

 

You said it's not striped out just a little rounded, that comes from not keeping the allen wrench square in the bolt. You have to have a set of allen sockets if you are going to own a Harley. Go get a set (they don't cost that much)put an extension on the socket put it in the bolt give it one or two sharp raps with a hammer this will force the socket it as far as it will go an it could brake any rust loose between the bolt threads and the hole. Then put a ratchet on the end of the extension and keeping it straight with the bolt give it a good twist. Don't be a ***** about it get after it if it breaksor totally stripsthen take it to the dealer; the wayI see itwhat do you have to lose by trying.

 

Hi all,

A little heat would help with the loctite and here is the method. If the allenbolt is striped on the outside edges straiten it with a hammer thenuseing a crisp allen socket or better yeta shortpiece cut from an allen wrench inserted into a socketand an old breaker bar.Insert the socket in the bolt and put tension on the breaker bar then hammer on the end of the breaker bar near the socket at the same time, done.

 

Buy the allen set for ratchets at Sears. It works great. No need to put standard Allen in at weird angles. Keeps bolts from rounding.

Then replace the bolt when it come out this time. This will help you avoid future headaches!

 

Is the bolt out yet?

YRMV