G'day All.
While trying to remove the valve cover I found that the front most of the 6 allen bolts was stuck. 90min later of struggling and teasing I had rounded it.
Does anyone have any ideas on how to remove it from.the confined space.
As it is under the front of the frame, behind the horn, I can't approach it from the top to either drill it out, cut a flathead slot, or drive an oversized torx into it.
I have tried to come in from the side (<45⁰) to try and push it with a nail punch and then chisel. The punch just kept slipping and the chisel cut the edge of the bolt to the top of the cover without moving it at all.
Any more ideas? I really don't want to drop the engine out to remove 1 stuck bolt!
Pics. The orange punch shows location and angle.
https://imgur.com/a/7nnnELI
Cheers
Can you get a dremel in there with a cutting disc to cut a flat head into it? Or remove the exhaust and use a 90 degree adapter on a dremel? Or a drill with a 90 degree adapter to use a left hand drill bit?
Other than those strategies I fear you may have to remove the engine
I ended up getting it. I noted on the corresponding bolt on the airbox side that it doesn't actually go into the engine so there was no real way I was going to 'break' anything.
I ended up going ham with a hammer and chisel and turned it 1/16 all the way out.
I put the other bolt in to test it. The old owner must have damaged it. I need to get a chaser or tap down it to fix things up.
Nice! Nothing better than the relief of getting a stuck bolt out of an engine. At least you avoided the usual chain of events that results in getting a hardened easy-out bit stuck in the bolt.