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I bought my bike about three weeks ago and I go to change the fluids and when I get to the primary and start taking out screws, I have a stripped screw,.. image that,. So I tried backing it out with extractors, didn't work, so I drill it enough to get the extractors to catch, and they just wouldn't bite, So I drilled the head off and tried everything under the sun to break that ****er loose. So now I got a screw broken off flush with the primary and am running out of options. So if someone out there can give me a little support on this one,, I'd certainly be obliged,, brothers and sisters. This is it, if you can see it
I had two primary cover screws with buggered heads. I drilled a hole in the heads and lightly tapped a torx bit into the hole with a hammer. The torx had enough bite to pop the screws loose.
Then I went to the hardware store and bought some stainless allen head bolts to replace the torx.
You have drilled off your heads so I don't know if this would work for you.
Good luck!
Since I don't know what "everything under the sun to break her loose" was.... I can only suggest:
1) hitting it with a good penetrating oil... like PB blaster. Hit it a couple times and let it set for awhile (overnight)...
2) Use heat. Either a heat gun, or better a hand torch
3) If it's still possible (pic quality not good), use an easy out/screw extractor... while prepping it for the eay put, use a left hand drill bit.. the bit may get it out..
If you've never used a left hand bit... I found this video on you tube, shows how to use the left hasnd bit.. his bolt came out, but if need be you could follow it up with a bolt extractor..
Why remove the primary cover? You don't need to remove it to change fluids ... but now you're committed to fix the problem ... if you can get someone to carefully weld a nut to the screw it will give you something to get a hold of and the heat may help break it loose ... good luck
Why remove the primary cover? You don't need to remove it to change fluids ... but now you're committed to fix the problem ... if you can get someone to carefully weld a nut to the screw it will give you something to get a hold of and the heat may help break it loose ... good luck
The OP called it the Primary cover, its clearly the Derby cover and YES you DO need to remove to change the primary fluid.
Not sure if this is the OP's case but; this is a good lesson for all to not drain the fluid until you've gotten all the derby cover bolts broken loose.
Once you drain the fluid you're screwed until you get the screwed up screw out.
Next; everyone should have a speed handle in their tool box if not for any other purpose but to use to remove the derby cover screws.
A speed handle lets you apply inward pressure on the screw while allowing for better control of amount of applied turning pressure.
Lastly make sure the primary is heated up before you try to breaks the screws loose.
As Hattitude eluded too; heat is your friend when trying to break loose bolts and screws
Back to the OP's issue.
Put the derby cover back on without the screw and see if it leaks.
If it doesn't leak you could just leave well enough alone.
Try a reverse drill bit.
With these the drill bit is drilling into the bolt in reverse so when the bit grabs the bolt/screw it can sometimes turn the screw out.
Harbor Freight sells these bits, but I'd recommend getting a higher quality bit as you'll like only get one shot at this option.
Next; use an easy out- my experience with these is about 50/50 but for less than $10 at Lowe's it's worth a try.
The key here is to take your time and drill the needed final hole using incremental sized drill bits.
What you absolutely don't want to do is break the bit off in the screw, then you're screwed so take your time and let the drill bit do the work (in other words don't put much back pressure on the bit)
Next; drill out the screw and using a tap create a new threaded hole and use a slightly larger replacement screw.
Last edited by Bluraven; May 16, 2021 at 07:21 AM.
AMEN..LOL...been there done that
I forget what it was, but broke the bit and ended up buggering the chit out of it til I gave up and replaced .
Worst part is, I know better and simply got impatient while drilling w/small bit
to the subject and my backyard 2 cents
as mentioned, heat's your friend.
reverse twist drill (drill perfectly straight as possible by hand ) cause a little bend while drilling will snap a small bit quick
Drilling alone will give it some heat and if you're lucky, may even come out on the bit.
If not, go to Harbor Freight and buy a $5 dollar butane pencil torch .
Heat it before the easyout
Otherwise, Mr Dan (a guy I always pay attention to) in post #7 has the surefire solution.
Have a professional with the tooling and knowhow to doit
I do wonder though...if a derby cover bolt caused the OP that much grief, I wonder if any "surprises" would pop up pulling primary cover bolts...
Perhaps it is my monitor but pictures are sometimes difficult to decipher if the individual does not take a clear picture from far away and then another closer.
The far away picture allows you to see the area. The close-up allows you to see actual problem.
The year and exact model of the motorcycle sometimes helps too.
It looks like a derby cover bolt had head drilled OFF and threaded remains are now stuck in primary cover.
Removal of primary cover should be done.
The primary gasket is expensive bur it can be reused if it is not too old.
The drilled bolt might be cross threaded or someone use threadlocker on bolt.
Once primary cover is removed then use a soldering gun tip to heat remaining bolt a lot.
If it has threadlocker on bolt the heat will melt it.
If it is above your skill set then just take primary cover to a mechanic..it does not seem like a difficult job.
Keep in mind that with primary removed it may be possible to turn screw towards primary and remove it out the backside.
What actual bolt was on primary allen/hex or TORX.. Reason: many times the incorrect TORX size is used..T27 is not very common in many sets
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Broke screw
