Best way to remove case bolts?

[cosmohawk]

Still working on the '74 ATC90...into the motor now...

http://www.3wheelerworld.com/attachment.php?attachmentid=116210&d=1297096662

http://www.3wheelerworld.com/attachment.php?attachmentid=116209&d=1297096659

I've been here before with other old motors, but I want to find out the best / proper way to remove the philips head case bolts? These ones are really cantankerous, and I've been unable to get them to "snap" free.

Just don't want to tear out the threads.

Just wondering if someone can provide me with a tried, tested, and true method for removing them, without serious damage, or resorting to vise-grips...or worse.

Thanks for any info! :cool:

[zzmegad]

what about one of those impact screwdriver things, and maybe a little heat?

[cosmohawk]

Yeah...I was thinking that...probably the only thing that can do the job. Now I've got to go buy one!

[3wheelrider]

Those are a pain...Use a good impact driver and 3-4lb. mini-sledge. -Or you can use a flatedge steel 1/2" chisel and 3-4 lb. mini-sledge and carefully hit lightly the screwhead straight-on to extend the "+" on the screw to the outer edge of the screwhead. Then hit at an angle so as to loosen it as you hit. But use must be extremely careful not hit inline of your sidecase if the chisel does slip!:D:D I've done this many times without a problem and works everytime but the screwheads then look only a little boogered. I sometimes I replace them with the 8mm hex-style bolts from spare 185/200 motors.

[ceaserthethird]

That's Cake, impact screw driver :)

[Kfx-xc-racer88]

Theres a few ways , impact driver but make sure the bit is a good fit, a chisel on the edge to shock it around, or if you have enough room to grip it with a mole grips to start it off!!

i had one that was a nightmare recessed inside my garelli engine case a while back and the only way i could get it out was drill the head out and then when the cases were split i could grip the shank of the bolt and undo it!!

[edog]

Take a over sized Phillips head and tap it on there with a hammer just enough to wedge it in there. Then put a long extension on the socket and push with all your weight against it. This usually works for me. Or you can use a dremel tool and cut a slot on the head and try to take it off with a flat head..or is all else fails, take the bolt head off with the dremel.

[cosmohawk]

Thanks for the suggestions...just gunna take some effort. As you can see, I started, using the biggest philips head bit I've got, using a 3/8's rachet, and it still started tearing out the head. I'll try laying the motor on its side and try attacking it from there! Maybe full body weight will be required, plus a little tap with Mr. Hammer.

[tri again]

Those impact , 'hit with a hammer' type screwdriver things are only like 10 bucks and worth every penny if it saves one screw.

They used to be really expensive until their patent ran out so you should be able to find them almost anywhere.

Make sure the screw slots are clean, some say a little bit of abrasive, like valve lapping compound and make sure the bit fits perfectly.

Also make sure you twist the impact wrench in the correct direction before you hit it.

There's a cam in there that drives it cw or ccw depending on where it's set.

You can test it on something less critical since they are essentially 3/8" drive.

[250rAL]

On a tight screw,if there's enough head sticking up, I use the vice grips. In the long run it does less damage to the screw head.

[cosmohawk]

I tried Vise-Grips...reg and neddle-nose, snapped them on there TIGHT...and they both just kicked off, or chewed some metal off the head.

I like the impact screw-bit driver and valve-lapping compound idea.
Gunna try that route for now.
Will update!

[jays375]

Get yourself a new pair of mini Channel Locks.Also good for stripped out screws.Did you try mini regular Vice Grips?

[beets442]

Let someone that knows what they are doing, do it....ooops too late! Now you'll have to do it edogs way.