I Broke It!! Help
I Broke It!! Help
Alright gurus, Looking for a quick answer here, today I was changing the oil on my bike and out of my stupidity drained the oil for the primary instead of the crank. Great right, well anyways now I am tasked with removing the derby cover to refill the oil as my bike (07RoadKingClassic) doesn't have a chain inspection cover. All goes swimmingly until the last two bolts. They all had been a pita. but these two were not budging, avast I got one of the bolts out but the last one was rusted or stuck on there pretty well. I tried drilling it like the other stubborn torq to use a screw extractor and the bit snapped off inside the bolt. So having exhausted all other options this one last F*$&%*^ one is lodged for life. My question is if I replace the whole outer primary cover will I be in the clear again and if so where is the best place to purchase one? I see a couple on ebay, I.e.
http://www.ebay.com/itm/2007-HARLEY-...695b77&vxp=mtr
Is this the best route to go yall think? Open to any and all help I am really kicking myself for this one... Keep in mind with your suggestions I would need the derby cover as well. Thank You in advanceee
http://www.ebay.com/itm/2007-HARLEY-...695b77&vxp=mtr
Is this the best route to go yall think? Open to any and all help I am really kicking myself for this one... Keep in mind with your suggestions I would need the derby cover as well. Thank You in advanceee
Road Warrior
Joined: Jan 2012
Posts: 1,392
Likes: 21
From: Delaware
Damn that's not good. If you've completely given up and want to go with a new-to-you used primary cover my only advice is look closely at the bottom of the one you're thinking of buying. When a bike goes down on the clutch side the area below the derby cover almost always gets some damage. It's rarely visible when on the bike.
Road Captain
Joined: Sep 2011
Posts: 541
Likes: 3
From: Sherwood Park AB Canada
If you can get the broken bit out, get yourself a titanium nitride bit and try drilling it again. I would bet you will be able to drill it out and retrieve the messed up screw with an easy out. Or, as suggested, take off your primary cover and take it to a machine shop. They can drill that sucker out on a drill press in seconds. Much cheaper that a used, new to you, primary cover.
Seasoned HDF Member
Joined: Jul 2011
Posts: 27,096
Likes: 4,673
From: Frozelandia, Minnysota
I've gotten broken bits out by drilling smaller holes alongside it; weaken the material enough, and you can rock the broken bit by hitting it with a punch sideways and work it out. If it's in well below the head of the screw, that might not work, but then if you're really careful, sometimes you can weaken the head till you can knock it off, then pull the cover and have enough sticking out to grab with a vise grip. If you do try more drilling, just be careful not to drill into the cover material under the screw head. A very experienced welder with a fine touch can sometimes weld a bit of metal onto the broken bit and pull it out. That screw is going to be difficult because whatever you do, you don't want it scratching up the cover; with cosmetics to worry about, it's always harder. But even if you have to pull the primary cover off, you should be able to have that bit removed without replacing the cover.
Outstanding HDF Member
Joined: Jan 2010
Posts: 2,916
Likes: 31
From: earth
Lots of ways to remove that last, what did you call it, F*$&%*^. And repair the threads if they are damaged from your attempt. you'll have to do some research to find someone local and weigh the cost of removal of the broken bolt with broken extractor, compared to replacing the whole outer primary cover. Doesn't help now but you might want to invest in a manual impact for that initial "breaking loose". "Best" course of action depends on how you value your time and money.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
Any small machine shop, custom shop, indy should be able to remove the troublesome bit and screw. Ask or phone around and just take the outer primary cover in. Buy new screws and gaskets!
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Outstanding HDF Member
Joined: Dec 2007
Posts: 2,403
Likes: 20
From: Indy
If you pull the outer off , I bet you could get the end of the bolt with a pair of vice grips , and turn it out.
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Seasoned HDF Member
Joined: Apr 2010
Posts: 9,556
Likes: 7,905
From: Long Island, New York
Take the primary off and try all listed comments on the bench. Sometimes half the problem is working on the thing in a bad position. On the bench, flat with a drill press and all will probably be OK.
+1 that you might be able to get to the back of the screw with the primary off. Vise grip may be all you need, fingers crossed.
+1 that you might be able to get to the back of the screw with the primary off. Vise grip may be all you need, fingers crossed.
Seasoned HDF Member
Joined: Apr 2012
Posts: 9,980
Likes: 5,218
From: Michigan
Take the primary off and try all listed comments on the bench. Sometimes half the problem is working on the thing in a bad position. On the bench, flat with a drill press and all will probably be OK.
+1 that you might be able to get to the back of the screw with the primary off. Vise grip may be all you need, fingers crossed.
+1 that you might be able to get to the back of the screw with the primary off. Vise grip may be all you need, fingers crossed.
Since you broke your easy out trying to turn the bolt in a counter-clockwise direction, try very gently turning the bolt in a clockwise direction (from the inner side) and then back counter-clockwise direction.
Once in breaks loose, keep going back and forth a little at a time until the bolt is out of the threads.
Just keep in mind that the threads are aluminum.
If you're not confidant trying this, find a machine shop. It will be cheaper in the long run.