Stripped/Mangled Allen Key Head
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Cruiser
Joined: May 2013
Posts: 129
Likes: 8
From: Norfolk
Stripped/Mangled Allen Key Head
I am trying to remove a Kuryakin Hypercharger that was installed by the previous owner of my Sportster so that I can get to my carburetor. One of the mounts that holds it to the engine is being held on by a ridiculously tight allen key. I stripped the head out badly trying to take it off (using the correct size allen wrench). I then tried the hacksaw/flathead screwdriver trick, and accomplished nothing except breaking a few small chunks out of the surface of the bolt head and further mangling it. My only idea at this point is to try an easy-out, but the hypercharger itself is blocking my work angle. I'm running out of ideas, and getting nervous about this bolt. I don't want to mess it up so bad that I can't retrieve it. Help me please!
Stellar HDF Member
Joined: Nov 2007
Posts: 3,364
Likes: 110
From: Mesa, Az.
Dremel tool with a cut off wheel will remove the head of the bolt, remove the Hypercharger and vice grips to remove the bolt.
It it still won't come out, double nut the bolt or weld one on the bolt.
It it still won't come out, double nut the bolt or weld one on the bolt.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
Can you get a small chisel and hammer in there?
Place the chisel on the side of the head,hit it with the hammer to try to unscrew it.
Place the chisel on the side of the head,hit it with the hammer to try to unscrew it.
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Road Captain
Joined: Jul 2009
Posts: 523
Likes: 4
From: New York
Sears sells a set of stripped bolt head extractor sockets. They look like regular sockets until you look inside the business end. There are a set of hardened reverse flutes. You select the appropriate size for the bolt, tap the socket on the bolt head, set your ratchet wrench to remove and have at it. The reverse flutes bite into the head as you work the ratchet to remove the bolt. I have used these a few times and they work great!
your PO may have used locktite on the bolt. A little heat will soften it and then you can use the above sockets.
your PO may have used locktite on the bolt. A little heat will soften it and then you can use the above sockets.
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