Stripped Hex Bolt on Clutch Master Cylinder

[The ModFather]

On 2005 620 I'm trying to remove the Clutch Slave Cylinder so I can get the Front Sprocket off to change it out for a 14T. All the bolts came off fine except the bottom which is stripped so my allen wrench just spins in it. Any tips on how I can get this bolt out?

[The ModFather]

Okay I think I found an approach searching through google. Gonna take a Bremel and put a slot in the head so I can use a regular flat head screw driver. If someones got a better idea lets hear it.

[Dirty Duc]

I've changed the front sprocket on my 800 (should be the same case and slave cylinder as your 620) without needing to remove the slave cylinder... Is there something I am missing here?

[AdmiralKit]

If the bolt is spinning, what good is it going to be to change it so a different type of lever applies force to it?  Since it's just the clutch slave, my first recommendation would be to put the allen wrench in the bolt, start pulling the clutch slave off and use the allen wrench loosen the bolt if it catches any more threads.  Second recommendation would be to see if you can't find an especially strong magnet and use it to either extract the bolt or to magnetize your allen wrench so it will pull the bolt with it.  Third suggestion would be to get a bolt extractor kit, which is essentially a tapered reverse-threaded drill bit and then buy a new bolt... you're going to need to fix those threads regardless, though, so you might as well figure out which helicoil kit you need.

[The ModFather]

Bolt isnt spinning the allen wrench is spinning in the hex socket on the bolt cause the socket is stripped.

I saw on the "How To" in the tutorial section on this forum for 14T Sprocket the step that said remove the Slave Cylinder and I thought "Why?" it looks like the front sprocket could come off without removing the Clutch Slave Cylinder but sure enough the chain on the front sprocket is hitting the Clutch Slave Cylinder when I pull it forward stopping it from coming forward and out. I am putting on a new chain so I figured I could cut the chain and probably get the front sprocket out without taking the Slave Cylinder off but I dont like leaving the bolt with the stripped head in place so I'm going to try the Dremel trick to get the bolt out tomorrow as my Dremel battery was dead and is charging. Update after I give this thing a shot. Worst case scenario I cut the chain and try and pull the front sprocket out without taking the Clutch Slave out.

[Dirty Duc]

Ah.  I see.

If you are changing the chain at the same time (like I did) then the sprocket comes straight out without mucking around with the slave cylinder. 

If it really bothers you, an E-Z out may do the trick.  just pick one that barely fits, and hit it with a hand impact driver to break it loose.

[suzyj]

A technique that I've used on stubborn allan key bolts is to get a torx driver that just barely won't fit the hole, and force it in with a couple of taps with a hammer, then turn that.

[bdfinally]

^+1^

[garryc]

perfect situation for a grabbit
http://www.justtools.com.au/prod3952.htm