This is what I had to do when this happened to me years ago. The only
way its going to come out is by weakening the threads grip on the case
itself. First you have center punch a mark as close to the center of the
screw as possible. Hopefully you have a good drill index with close
increments on the bit sizes. If the screw size that broke off is 1/4 inch
use a bit a bit a little smaller than 1/8. Try to estimate the broken off
screws depth. Drill a hole in the screw as deep as the depth you think
it might be. Drill speed should slow because the screw is probably
graded. Next use the next size bit in your index and drill the hole the
same depth as the last one. The idea is to get the broken screw as
hollow as possible. Once you feel the there is very little thread left
then use an easy out on it. Also be sure to WD40 when you are
drilling the hole out and using the easy out. When the thread finally
comes out there might not be enough thread left to run a screw in.
This is also what happened to me. Most good nut and bolt dealers
sell Heli-coils. The kit comes with a bit to drill out the hole and a
tap to thread the hole and insert the heli-coil.
This was my scenario and it worked but it was a process but it saved
me from having to take it to a dealer where you know they are going
to BEND YOU OVER big time by the tune of $75 plus an hour.
If you try this remember the idea is to get the material in the center of
the screw as thin as possible so that the remaining thread will come
out easily with an easy out. Good luck.

 

Or you could just trade it in on a New bike...

 

A couple good posts on here to help you.

You definately don't need to be drilling in the sides. Thats exactly how you screw your threads up and need heli-coils. I can't exactly see if its raised in the center and thats why you can't drill or what......But, if its' raised up or jagged at all, don't bother center punching it, you'll just slip off. Get an actual punch and flatten out the area just a little.....don't beat the bolt through the threads.

You need to drill a pilot hole in the center...1/4 deep or more preferably...the deeper the better, unluss you're going to hit into the casing. So, hopefully you've got an idea of how much bolt is left in there. Once you get the pilot hole....say its a 5/32 bit....step it up from there and size it with your extractor.

You also need an actual good drill bit and do it right if you want to get it done. Cobalt bits will work. When you hit the screw extractor in....you have to HIT IT IN.....it needs to grab. You're not going to break it off unless its a sh*tty extractor. Once the extractor is in....hopefully its long enough for you to grip it with some plyers or maybe the back end of the extractor is a socket fitting. It will come out if done like this. PB blaster will help a little and free up the threads. It has to be drilled out obviously, so, I wouldn't even worry about helicoils unless you jacked threads. If you simply get it out like this you won't need helicoils.

 

pick up a left handed bit , drill out and and easy out.........some times the left handed bit will grab and spin it out if your lucky...take your time and it will come out......also when you put covers on into aluminum, buy yourself a short 3/8 rachet to tighten , no need to over tighten bolts/screws in aluminum........

 

Sometimes dealing with the "principle of the thing" overshadows a little common sense.

I had a stripped screw on the primary cover on my sportster...spent hours trying to get it out including two trips to the auto parts store for more extractors, etc. Still couldn't get it to budge.

I said to hell with it and drove it over to the local dealer. Service manager took it right in and they had the old one out and a brand new one in it's place in about 15 MINUTES!!! Charged me a twenty dollar bill.

Best twenty I ever spent.

 

I am thinking about going your route BassCatcher... have wasted already too much time with this damn thing!

Thank you all for the help!
Might give it one last try tomorrow before bringing it in to the dealer on Saturday!