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[spydglide]

If you've got one, or can borrow one, you might try a electric etching pencil.  You've seen them, those things used to scribe marks, names, whatever on metals or plastics.  It has a very rapidly vibrating small, hard tip but is easy to control.  Might be able to "massage" it loose.

aaahhhhhh.    har!  spyder

[RedFXR2]

I knew somebody would read it that way, it was just a question of who.

 

[Midnight Rider]

If you've got one, or can borrow one, you might try a electric etching pencil.  You've seen them, those things used to scribe marks, names, whatever on metals or plastics.  It has a very rapidly vibrating small, hard tip but is easy to control.  Might be able to "massage" it loose.

Just keep it well hidden....

[Gettinold]

Just keep it well hidden....

Check the sock drawer. 

[spydglide]

uh oh........   har!  spyder

[Gettinold]

I was working on my wife's bike and broke off the ball end of an Allen wrench in one of the primary inspection cover screws.  It went in tight, and then just broke off.  Must be I don't know my own strength!  Now I've got a small hexagon ball stuck in there! 

Any ideas how to get it out?  I can't reach it with any kind of pliers, and I can't get another wrench in behind it to take it out and replace it.  Will heat help?  Don't want to damage the aluminum around it.

Well did you get it out.

[Twolanerider]

This is why I cringe sometimes when using ball ended allen wrenches.  I'll only use them if I have to enter the bolt at an angle.  Otherwise always use a solid allen tool.  The little ball ends will snap off.  Sorry you've got the hassle to deal with.  If it makes you feel any better; at least one other person here has been there and done that.

[hd-dude]

This is why I cringe sometimes when using ball ended allen wrenches.  I'll only use them if I have to enter the bolt at an angle.  Otherwise always use a solid allen tool.  The little ball ends will snap off.  Sorry you've got the hassle to deal with.  If it makes you feel any better; at least one other person here has been there and done that.

Make that two

Seriously even the best ball tip allens will and do break, (just ask my Snap-on man how many 3/16" ones i've replaced) Only use when needed. The problem is that there are so many damn bolts that you need them on an HD.

[courter]

Sorry it took me so long to get back to this -- my persistent procrastination (and my new bike arrived  ) so working on the Sporty has not been on the top of my list.

In the name of science, I decided to try the remedies listed here before getting radical with the darn thing:

• She's ridden it plenty, so I figure the vibrate it loose possiblilty was out.
• I used my engraver for a long time.  Tried prying on it and broke the tip off my pocket knife in the process .   No luck.
• I didn't have a good way to heat just the bolt head, and aluminum melts at such a low temp that I bagged the idea of hot/cold.
• I drilled a small hole next to the allen ball, and after a LOT of work was able to pry it loose.

I could not loosen the allen screw, nor could I loosen the other one, so I drilled the centers out.  Unbelievable how frozen in place they were.  I still had to drill the center of the remaining stud and use an ez-out to remove the threaded shaft.  Thankfully, there was no damage to the primary cover or the inspection cover.  Only problem was that there was a few days between starting and ending the project, and Mama decided to go for a ride  , but she quickly noticed the extra noise and the oil spraying out so she parked it.

Thanks to all of you that offered suggestions. 

DISCLAIMER:  There are no right answers.  Seek them lovingly.  (in honor of Rhino)