Stuck TORX bolts

Hey guys,
I'm tryin to get in and assess weather or not I can do the "shortcut" starter clutch fix through the stator housing. I got the stator and coils off last night and went to work on those 3 torx screws with the bit driver, no go. I got out the manual impact driver, still a no go. My next try will be a torx socket for my 1/2" air impact wrench. Any other suggestions? I've put a little WD40 on them to help loosen them up, but I doubt its doing any good.

 

Might try PB Blaster it's a penetrating lubricant, then tap them a couple times to work it in.

 

be careful t
hey chew up real easy and are awkward to drill out

 

Assuming you will be replacing the seal and the seal-carrier o-ring, you ought to try to gently heat the screws up. I had problems with mine but my impact driver worked out. Best of luck.

 

Get some of that Kroil stuff in the orange spray can.

I'm telling you, that stuff is liquid magic. It's never failed me yet on a stuck bolt or screw.

Spray a little on, let sit overnight, then try again.

 

They put a lot of Lock-Tite on those at the Factory. You'll be OK with that Impact Gun provided you are using a Torx Bit with low mileage on it!

 

nothing releases Lock-Tite like heat

 

Here is the persuasion I applied:




It worked!!! Now I have to figure out how to get that next piece out!

 

So didn't mean to do that!!

 

Search: Starter Clutch Shortcut

Author: RedCentre3

 

search author bike-man-man
i tried it once, and gracefully accepted failure

 

Thats exactly what I'm headed tword!! Now I have to figure out how to get the plate that the torx screws were holding off... this one:

 

Don't mean to threadjack, but I feel it's important to mention that PB BLASTER is the best penetrating oil on the face of the planet. I've used them all (I run a small hardware store) and this one's the best...by far. Every garage needs a can of this.

-AM

 

pb blaster is the shizznit, it works best if you spray it on the stuck bolt and let it sit overnight before manhandleing the bolts. it does rock

 

The plate will pull straight out with little difficulty.

 

Those TORX Heads are shouldered and in there flush.

I use a TORX 3/8th's Socket on a 3/8th's to 1/2" Adapter on a 6-inch long 1/2-inch extension on a 18" long 1/2-inch breaker bar.

I put the Torx Bit into the Fastener.
Position the Handle of the Breaker Bar as close to 12 O'clock as the Fastener will permit.

Pre-load a great deal of undo turning torque on the Breaker Bar.
Then, ... I smack the Breaker Bar with a heavy, Hardwood Hammer Handle.

I don't give it highly repetitive, Low-torque Impact.

I give it sudden and "Violent" HEAVY Impact while the fastener is already under a Heavily applied turning torque.

The fastener usually "Budges" out a tiny bit ... but remains firmly attached.
It takes several blows to get the fastener to loosen enough to be removed with heavy torque minus the heavy Impast.

 

I used a hand impact (hammer driven) to loosen mine. Unfortunately, I was using a security type torx bit with the hole in the middle. On the last screw the tip of the bit broke off in the head of the screw, twisted in there by the torque of the impact. It wouldn't come out! I ended up drilling three 1/16" holes in the head of the screw, around the broken bit tip, then used a punch to knock the bit tip out. Then I drilled out the screw head, then used drill bits progressively larger until the screw was out. Cleaned up with a tap and life was good again. I never did figure out how to get the starter clutch apart to where I could replace the rollers, springs and cups... :evil:
I repalced the battery (which it needed anyway), and the starter clutch hardly ever slips now :lol:
And yes, the factory used the super duper loctite on the torx screws!

 

A small pry bar wedged under the outside lip should free that sucker up. It has an o-ring seal for the seal carrier as I recall. If your replacing the seal, just pry out the seal (DO NOT scratch the rotor shaft), the seal carrier ought to pop out easily.

 

I think I've decided to split the cases anyway. I'm pretty sure the chain guide has disintegrated. I tried splitting the case once, couldn't get it to budge.. I hope I can figure it out.

that and have GOT to find my service manual, it seems to be lost.