front sprocket cover
 

I want to remove the front sprocket cover to clean out the oily gunge that collects behind there but I can't shift the bottom bolt which has a fairly shallow socket for the Allen key. Allen key already slipped trying to remove the bolt so don't want to damage the head. Any suggestions welcome.

Re: front sprocket cover
 

Insert Allen key ... preferably a 'straight one, hold it in tight, strike the end of the key with a hammer ( not too hard) and this generally shocks the bolt and the crud that's gripping it.
May take a few goes but always works for me. Btw ... I always soak the bolts for a day or two before starting on it. And ... do it when it's completely cold, the alloy bolt hole will 'tighten' up when it's warm/ hot and so grips the bolt a bit tighter.

Re: front sprocket cover
 

If above doesn't work and/or you already stripped it. Try the next size up allen in standard size and hit it in there with a hamer. Say a prayer and turn it slow.
When that doesn't work get the chisel out, scar the head so you can get it with a flat head bit on a hammer drill. Turn slow.

I use heat on stubborn bolts, so to each their own on that advice.

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Re: front sprocket cover
 

stop using allen keys and get yourself a set of allen sockets (preferably 3/8 or interchangeable 1/4 sets) or a set of T handle. same goes for the screws on Jap bikes as they are not philips but JIS.

if you have a dremil then you can chamfer the end (each flats) of a next size up and hammer it in. btw those "bull nose" T handle are good for this.

its not the fit of the key that causes problems but the leverage on the key.

Re: front sprocket cover
 

Larger torx bits can be hammered into hex heads if it begins to round off.

Does it have a metal sleeve? if not you could always snap the cover and then use heat to get the bolt out. If it's a curvy I think I have a cover knocking about.

Re: front sprocket cover
 

Thanks for the replies.
What are Allen sockets, I thought the socket was the recess in the bolt head ?!
I have a set that incudes extension bars that the Allen key head fits onto!
My Suzuki dealer has offered to remove the bolt if I call in with the bike so I might do that anyway (and hope I haven't damaged the head too much)

Re: front sprocket cover
 

It's a Male Allen socket. Similar to how you get Male/female torx sockets.

Re: front sprocket cover
 

He means a socket as in goes on a socket set, but with an Allen male part (!) on the business end i.e Allen key

Re: front sprocket cover
 

Ok ,thanks. I have a set of them with a small ratchet handle or an extension bar with a tee handle option.
The recess in these small dome head Allen head bolts aren't deep enough in my opinion to get a good enough hold though.

Re: front sprocket cover
 

Clean the crud out of them as well