broke off the engine/clutch plate

Diver · Nov 19, 2010

I stripped the screws on this cover, then broke off a "screw extractor" bit in the screws- then attempted to drill the pieces out. Then I lost it and started beating on the plate with a hammer (it came off).
There was only one screw that came off.
With what you see here- the engine will still run correct?

Can I build or do something to disengage the clutch or not- suggestions?

Mind_Reader7 · Nov 19, 2010

Holy ****. Good shot!

Al.Fisherman · Nov 19, 2010

Need to keep tools out of your hands....Don't be so cheap and use that piece of junk...buy a new/used gear cover. There is a way to mount the new cover and work well. How many non screwed up holes are left...1 or 2?

Diver · Nov 19, 2010

1 screw got out, in the upper right. The other screws never moved- It's like were tighten down with a torque wrench. I bought and use a "screw extractor" bit exactly per instructions and THAT broke off too- so I tried just straight drilling without much success.. then it was hammer time on it with my girl screaming "No, don't break it!".

I was wondering if I can still ride with y'all? Can it be fixed?

BarelyAWake · Nov 19, 2010

Well... w/o the cover & clutch actuator you'll not have the clutch ofc... but if you can start it from a dead stop with the engine engaged pedaling it outa work just fine, stalling when ya come to a stop of course...

Try a left hand/reverse drill bit (available at any good hardware store) slightly smaller than the screws you're trying to remove, sometimes that'll back them out all by itself - if not, drill out the holes to their proper size/slightly over & tap new threads in & it'll be fine.

Bit of a pain it's true, next time try an impact driver like this: Amazon.com: Lisle 29000 3/8" Hand Impact Tool: Automotive - ya even get to use a hammer w/it lol

Goat Herder · Nov 19, 2010

Getting a broken screw extractor out can be a real pain but it is do able . Something hard like a small drift punch sharpened to a point start hitting at it slowly and meticulously. The extractor is brittle and will eventually chip out of your way. Delicately hammer at it with the sharpened punch until all of the extractor chips out.

With the extractor in the way a drill bit will not drill through it. It is a bit brutal on one patients but very do able!

Wear some safety glasses good luck!

Bikeguy Joe · Nov 19, 2010

Next time- Use some penetrating oil, and if you don't have or can't afford an impact driver put the (good fitting) screwdriver on the screw THEN get out your hammer and give it a few smacks.

If you can't get the screws/extractor out, use a few small pieces of flat aluminum and bridge across the cover to the case.

Charged-Reacter · Nov 19, 2010

I am going to take a wild guess and say that is a powerking shop
engine on e-bay because I just recently purchased one from powerking
and man I haven't got those screw bolts loose yet...lol

hurricane · Nov 19, 2010

LOL Diver, since you all ready took the hammer to this plate, finish the job and grab a torch and melt this bad boy down before it makes you mad again. LOL

Al.Fisherman · Nov 19, 2010

Actually that wouldn't be a hard fix. First you would need to get a new gear cover plate. Second drill two holes approximately where I have the solid holes marked but in the coil cover. Where the two rectangles are make tab that will go from one cover to the other (round corners). Bolt these two tabs onto the coil cover plate, bolt the gear cover plate on with the one 4mm bolt, then bolt the coil cover plate on with the 4 6mm bolts.

Also another way is that two holes can be drilled into BOTH the coil and clutch covers (plenty of room in both covers), join with tabs as described. Install as one cover. Some sort of shim will be needed on the gear cover under the tabs as the covers protrude at different heights.

No matter which way is used I'd replace the 6mm bolt in the gear cover with a longer one that you can get a nut behind it. Possibility drilling out hole to do away with the threads. This will eliminate a stuck screw problem in the future.

By the way I have 2 Powerking engines and couldn't be happier with the service I'm getting out of them...I have had to do absolutely NOTHING, to either since installed...NOTHING, whatsoever as far as repairs, adjustments, or re torque.

Venice Motor Bikes · Nov 19, 2010

I would use a Dremel tool with the tiny cut off wheel to make a new 'slot' across the top of the screw heads; then use a straight slot screwdriver to remove the screws.

Goat Herder · Nov 19, 2010

In the Air Conditioning business on the compressor manifolds I learned years ago to give the Allan bolts a quick smack with a hammer and punch before trying to remove them. Made it easy every time.

Your right Venice we missed that!

hurricane · Nov 19, 2010

man you fellas took all the humor out of this post, you all are like so serious and offering help.

the guy took a hammer to his engine for goodness sake, cant we just point and laugh at what he did ? LOL laff

corgi1 · Nov 19, 2010

it looks like there is still potmetal on the two screws,if so could the mag cover be removed and the pot metal removed from the screws and vice grips used on the screws,any more stuck screws need the head drilled off before hammering and use vice grips,then replace with good allen heads

corgi1 · Nov 19, 2010

hurricane said:
man you fellas took all the humor out of this post, you all are like so serious and offering help.

the guy took a hammer to his engine for goodness sake, cant we just point and laugh at what he did ? LOL

its ok ,some people get excited faster than others,but those do need to keep the hammer in a lock box at the oppisite end of the garage,,i know it's not funny ,sorry xct2

Goat Herder · Nov 19, 2010

Somewhere is a picture I linked that was a motor someone had thrown it from a second or third story window then preceded to to hammer it. In the picture it looked like it was still twitching. For the life of me I cannot find it to link the photo. It was my favorite desk top background picture for a wile.

hurricane · Nov 19, 2010

thx corgi and goat,now you see the lighter side of this OP

Diver · Nov 19, 2010

Hey thanks for all the help guys! Great advice- great website!

Hurricane, I actually went to jail last night.. the engine some how got my cell phone and call 911, the cops showed up- the engine was in tears and I was denying EVERYTHING! Anyways, someone has to go to jail in these situations and now it looks like I'm facing both a domestic violence (I was violent- in my home) charge and a property destruction charge (it was property). I'm looking at a very expensive ($3,000) DV class now..

So guys, no joke- don't beat on your HT's- it'll end up costing you a lot more than $150!!

hurricane · Nov 19, 2010

Good humor Diver,you made my day with that post.

Now you are deserving of all the help these fine men/women have to offer for fixing your broken plate.

2door · Nov 19, 2010

Next time try just a little heat on the aluminum casting. It will expand more than the steel fasteners and help loosen them. A sharp smack with a hammer on the screwdriver will also give you a little advantage.
Frustration with mechanical things is understandable...they do conspire against you. After working with them for over 50 years I've come to the conclusion that some of them only respond to force. It just becomes a matter of what you can afford.

Tom

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