starter clutch on 82 twin m1

hey guys, got the starter clutch off a few days ago. got the rebuild kit that i needed with new bolts. problem is, is that no matter what i try i cant seem to get the old ones off. is there any ideas that could help me? the allen heads on the old bolts are completely rounded out. thanks for any help.

Get some good penetrating oil like Kroil or PB Blaster and apply it after heating up the stuck bolts with either a hair dryer or a propane torch(don't catch the oil on fire) and then get a Torx bit, driving it into the rounded out allen head bolts. Use a 1/4" or 5/16" wrench(which ever fits the Torx bit) and a 3/8" breaker bar with a socket to fit the bit to break the stuck bolts loose.

New bolts will need a light coating of the silver anti-seize on the first few threads so they won't bind up due to dissimilar metals.

thanks. will try it tomorrow. appreciate it. I should of thought of that before but I didn't know if heating it up would demagnetize the magneto.

Keep the heat localized(a hair dryer on high works best)and then the penetrating oil. Tap the stuck bolts with a hammer to distribute the oil, drive in the Torx bit & give it a few minutes to work and then use the breaker bar.

well back again. the torx bit got the bolts out in like two seconds. didnt even need pbblaster or heat. problem is though, that my starter clutch is still stuck to the back of the rotor? any ideas on how i could seperate the two. thanks for any replies.

thanks for all your help guys. starter clutch is fixed and working perfect. gotta charge the battery up though really good because it was pretty much dead.

When the battery is fully charged, take it to a shop for a load test,this will determine if any of the cells are marginal/bad. Also get a floating charge tester(a small series of balls floating in a glass tube). You draw in a small amount of battery fluid, and the number of balls floating tells you the health of the battery(I believe it's called a Hydrometer).