I got problems

[dave76]

I'm currently putting a new clutch in boys 97 Warrior but unfortionatly three bolts broke off the clutch cover in the case, and after I got the cover off I tried spraying it down and letting it sit, and then trying to remove what was left with a vise grip, but that didn't work out as they just broke right down to the case. Any ideas???

 

[atv]

drill them out? BUT BE CAREFULL NOT TO **** UP THE THREADS! dunno really... maybe welding somthing to it to turn it?

 

[dave76]

They wont turn, it's like there seized in, no one really took care of this quad so it don't surprise me.

 

[jasonp]

take a nut that is a little larger then the bolt itself or I should say about the same size. Hold this nut with a vise grips. This is where your going to need a wire feed welder. Weld the nut to the bolt, try and get as much heat in or on the bolt. The heat will break the bolt loose, then you can turn the bolt out with the nut. This is the best way I've found to do it... otherwise you'll have to drill them out and tap. I've never had much sucess with that.

 

[dave76]

That don't sound like to bad a idea, I may give that a try, I have a Lincoln 140 mig machine. I really don't want to try drilling it and helicoiling it, because I don't want to take the whole motor out. Plus that only really works if you drill it perfectly strait.

 

[jasonp]

I agree dave. At are shop, I can't count how many times I've seen this done and it works! I know I've done it and it's impressive how well it works. It's quick to. Don't have to drill and tap and all the ******** inbetween as it never works out for me. Make sure and disconnect the battery before you start welding to it.

 

[dave76]

Well tomarrow is another day, I got killed at work today and then got killed working on this quad at home so I'm beat right now.

 

[teamexileracing]

worst case scenario, get a new case.

 

[jasonp]

worst case scenario, get a new case.

screw that man, then you have to take the whole engine appart.

 

[2fast4urass2005]

GET SUM EASE-OUT'S THEY WILL COME OUT. Lat resort drill it out and get a re-threading kit and just make sum new threads after u drill it it will be fine the key to this is just take your time and dont get pissy.. lol good luck

 

[chad021]

buy a set of easy outs, what you do is drill a smaller hole in the middle of the thread and than screw in the easy out which is reverse threded so as it tightens it breaks the bolt loose. Or take a screw driver or chisel and beat the screw till it turns.

 

[jasonp]

Ever break a easy out off? Good luck getting that out. If he broke the bolt off and then broke it off again then I bet an easy out will break as well. You need heat.

 

[jasonp]

Ever break a easy out off? Good luck getting that out. If he broke the bolt off and then broke it off again then I bet an easy out will break as well. You need heat.

 

[dswwarrior350]

Put it back together. The other bolts will put enough pressure on the case not to mention its on a high point so not much oil sits up there.

Im just waiting to get ragged on for saying that from everyone else but from experience it wont leak.

 

[yamarider]

Yeah, i was getting ready to say the same thing dsw. There's what, like 13 bolts holding that cover on, and really no load at all put on it? Mine has a couple missing because even with the torque wrench set to 7 lbs, the heads on those cheapass bolts just twisted right off. I just put the gasket on with the blue RTV sealant like normal, and there's not the slightest bit of seepage coming out of it, and it's been a year.

 

[dswwarrior350]

Im glad im not the only one. I just figured its not worth all the money and trouble for something that doesnt even really need to be fixed.

 

[teamexileracing]

[quote:lm3qsgug]worst case scenario, get a new case.

screw that man, then you have to take the whole engine appart. [/quote:lm3qsgug]

Have you ever done it, its not that hard once you get the flywheel off everything stayes togehter and you can slide the case right off and put a new one on, but thats the other side im talking about, ive never done the right side but it should be the same just with the clutch and all those components in there instead of the fly wheel. Its really not that bad, just it scares you thinking you might do somthing wrong.

 

[dave76]

Put it back together. The other bolts will put enough pressure on the case not to mention its on a high point so not much oil sits up there.

Im just waiting to get ragged on for saying that from everyone else but from experience it wont leak.

Thats what I'm gonna do DS, I did weld a nut to the bolts and the nut just snapped right off again, and I welded it good. I don't think three bolts will make that much a difference.

 

[dswwarrior350]

Its going to save you alot of time thats for sure. if it leak then id worry about it.