Originally Posted by BAKERiSM
I just bought a used 07' Nightster and decided to change all the fluids. Oil was going great untill I tried getting off the primary chain inspection cover. The allen bolt was already stripped so I tried tinkering with it and couldn't get it and as a last resort decided to use a screw extractor. After getting the extracter in there with my spirits high... It breaks off inside. Now I'm not sure what to do... Does anyone have any insight into this problem? Any help would be greatly appreciated!!!
By 'breaks off inside' do you mean the head of the bolt twisted off, leaving only the shaft of the bolt, flush or below flush into the threads???
IF YOU CANNOT get the cover off:
If that is the case, and you've never done this before, take this to a professional who is VERY skilled at doing these jobs. Ideally, find a machine shop, not just any normal mechanic.
They are going to have to drill out the shaft of the bolt, VERY carefully, clean out the remaining threads, and chase the old threads out with a tap.
If they can't get the old threads out clean, they will have to bore out the hole one size bigger and then tap new threads, or insert at a Helicoil to the OEM thread size.
Either way, you want an expert at this kind of thing to do this job for you.
IF YOU CAN GET THE COVER OFF:
Get the cover off and find someone who is a skilled welder, have them weld on a new head to the exposed threads (carefully!!!!). Use the new head to remove the bolt. If this one snaps off also, revert to the steps above.