Hey I was working on my sportster primary today and when i started taking one of the lower allen bolts loose the head just rounded out. I tried to use a bigger size and it didnt work. These bolts are tough because ive tried 4 or 5 different drill bits on so I could try to use an easy out on it but thats not working. Can anybody on here tell me the best way to get this bolt out.

 

Dremel a slot in the head and use a large screwdriver and a lot of grunt.

 

you can buy an extractor from just about any auto parts store. Should find one that's fit with out drilling.

Could be a good reason to buy the dremel tool too if you don't have one!

 

I did the same thing and I got a set of extractors from sears they fit over the head of the bolt and it comes right out, piece of cake

 

sometimes a metric allen wrench will work.

 

Take a small eaise out tool & grind the pointy tip off a little at a time till the large part of the eaise out gets a grip & back the screw out . IT may tate a few times grinding off the tip till it takes a good bite . Save the specially ground eaise out tool for later problem screws . just my thoughts . Good luck . Duane # 617849 Blue 08 Ultra born 8-02-07

 

Use a drill bit that is the same size as the bolt and drill it untill the head falls off . then when you be able to take the primary cover off you can use a pair of visegrips and heat to get the stud out .

 

I was actually thinking about trying it this way!

 

I got a set of craftsman damaged nut removers but im not sure the smallest one will work or not. I will probably try combo of all these suggestions.

 

I used this trick when changing my stock air intake and one of the heads stripped. It works well. Just be careful, those dremmels can get away from you.