Boxerworks.com

Hi all

Looking for some help here.

One of the 6 bolts that holds the clutch pressure plate in place has corroded. As such, the allen key just turns. That's what you get for riding all year round in the damp Scottish weather I suppose.

The question is: what next. How do I proceed?

The other 5 bolts are moving.

My toolshop is pretty well stocked, and includes:

Dremel
Angel Grinder
Impact drivers of different types.

If other tools are required I'll buy them.

If I end-up damaging the pressure plate it's not the end of the world, I can replace it. I don't want to damage the flywheel though.

I've walked away for now and am looking for ideas.

Cheers, Andy in Edinburgh.

I have been able to make a plan in this sort of situation by firmly tapping in a "torx" bit into the damaged allen socket head.
The light hammering action to force it in will also help to crack it loose.
We get those Torx bits here in South Africa reasonably cheap and they are nice and hard.
Good luck.
Rick

Another possibility it to dremel a slot wider than the allen and use an impact wrench on it.

And use some valve grinding paste or some other gritty substance between the tool and the bolt.

A long shot, but Is your hex key up to snuff? Commonly the edges at the end are rounded off which can tend to cam the key out of the socket, especially if the socket hole is shallow. I take the hex key to a grinder and grind the tip off which will let more good edge into the socket and reduce the camming action.

Also, is the key really as thick as it could be or is it a sloppy fit in the socket? Perhaps a slightly thicker key (manufacturing tolerance) could be found which fits tighter. Failing that, if the fit is just loose, perhaps the next size up key could be modified to fit better. To do that you would very carefully grind 3 or more flats down a hair to get a tighter fit. Of course it goes without saying to be careful of over heating during grinding.

And, as has already been suggested, hitting the top of the socket smartly with a hammer might help.

The last one I haven't tried, but I'll throw out there. As a desperate try you might try to arc weld ld a stee bar onto the very top of the socket. Heat might flow down the bolt and loosen things up. Easier said than done I'm sure, but you're desperate.


Ken

First I would try the grinding compound on a really good Allan key. If that slips, then go to the next size, which is probably American. Grind it to a taper and tap it into place with some of that grinding compound. I have always been able to get them out.

Is there a Whitworth sized Allen key? Might be easier to find in Scotland.

Thank you all, this is a great forum.

The torx idea was good but did not work, the corrosion seemed too bad and the best size just turned.

The fix was this. Take the dremmel (wonderful device), and cut a slot down the middle as advised.

I tried to use the impact driver, but it is hard to swing a hammer in there to use the impact driver.

So I took the tool from the impact driver and use it with a ratchet. It was hard but it shifted a few millimeters - a great feeling.

Overall, 5 winters since the last clutch service have taken their toll with corrosion on both plates and the spring.

Cheers and happy riding

Ken in Oklahoma wrote: Is your hex key up to snuff?
Ken

My daddy taught me that it was a poor craftsman that blames his tools.....

no point here....

it just came to mind.

bbelk wrote: My daddy taught me that it was a poor craftsman that blames his tools.....

Look out Harbor Freight! Here I come. I want one of everything!


Ken