I was putting the bike back together after tinkering with the stock air filter and while I was screwing the two outer fasteners back in I basically ruined them. Bad quality torque wrench. I'll be returning it promptly.

My question is: How would I go about removing it if they're stripped? I rode 15 miles this morning on highway and both seem to be in the same condition.

 

To remove them you'll probably have to cut the crap out of the ham can cover, and get a pair of vise grips on the bolt heads to get them out. You should be able to find a replacement easily enough, OR, you have an excuse to upgrade!

 

Could stay together indefinitely, or the loose fastener could fall off after another mile.

It is a PITA, but I would get it resolved asap.

Use a dremel and cut a groove in the head and hopefully a flat head screwdriver will get them out for you, without damaging your cover.

 

That's what I was thinking, but I don't have a dremel (yet). So my dilemma was do I go buy the dremel and fix it myself. Or do I get the DK Outlaw air cleaner that I wanted anyway?

I do kind of really want this though and at $90 it's financially more doable:

 

It would be great to see you rockin an Outlaw A/C, you would like the extra power too.

But you still gotta get that ham cam off of there anyway.

Harbor Freight has some inexpensive (won't last as long as a Dremel brand, but if you don't use it much anyway, it won't matter) Rotary tool kits.

Here's one for $10.49
http://www.harborfreight.com/80-piec...kit-97626.html

 

I say Dremel and Outlaw, but if you decide to stay stock I have a complete intake on the cheap, and I'd part it out for ya. I didn't pay the hamcan setup any attn, but seems like those thread into the stock filter don't they? Might just be out a filter and the screws.

 

Quick inspection looks like the only damage may be to the screws. I'm probably going to go buy some easy out screw extractors for my 3/8" drive rachet and dig them out by hand. Then go pay the stealership $5 for 2 screws.

 

Good deal.

 

I work on c-130's, and crew chiefs get stuck screws all the time. drill a nice hole, use an easy out and a hammer. Just make sure you use the right drill bit. If the one screw is just spinning, just buy a ball file for your drill and drill the head off. Be careful not to drill too far into the head, drill and inspect.

 

I would drill, carefully, deep enough to get the easy out set properly. Good luck.