I recently had the she same problem with my timer cover as the wall thickness of the Willie G. is apparently thinner than stock. After posting on here and talking to a local Indy I was left scratching mt head. What I ended up doing was remove the good heads, then drilled out the bad head until nothing was left but the threads, (drilling out the head) thus allowing me to remove the cover. I was then able to get the stripped out bolt with a pair of channel locks. Good luck and let us know how it turns out.

 

Thanks, I will try the impact driver, should have swiped it from my dad's tool box when I was home.

 

+however many on the impact driver. Cut the screwdriver slot and hit the driver. Works every time. Then get a torque wrench.

 

Yeah, good luck with the impact driver on such a sensitive part of your bike.... This was suggested to me with my problem but I shunned the thought as I DO NOT want to have to take my scoot to a machine shop after I screwed it up. I wonder how many of these suggestions come from experience as mine has.

 

Yep, been there, done that.

 

drilling head off worked well for me also

 

This has worked for me, except I use a couple sizes up from 1/4".

 

Ya suppose that part being "sensitive" is why it gets all bound up? If it is then I'm not worried about hurting it's feelings.

One of those suggestions came from the owner of a 40+ year old impact driver. In those 40+ years that driver has never caused a problem, but it's solved a lot of 'em.

 

as mentioned by several before above...
May wish to consider....
For the primary:
Several members in times past report that the dealers seem to drill the head off the damaged bolts ..
Remove the good bolts.
Remove cover
Then just use a pair of pliers etc. to remove broken bolt..
***caution may wish to protect areas were you are drilling just in case drill bit slips..cardboard & tape.

 

Listen man, I have removed 1/4-20 Allen heads that had heads that were stripped for 30 years in industrial work. 90+% of the time this will work. Get a ball bearing, hold it in the socket then whack it with a hammer a couple of times. Use an impact driver and make sure that the hex driver (allen wrench) is perfect not rounded at all. If you have to tap the driver to get it into the socket you did it right. It should come right out I've done literally hundreds this way. Don't know how many the guy who showed me that did before me.