stuck screws

[TyFerris]

im looking for advise for getting out Phillips head screws from the bottom end of the motor i tired one of those impact screwdriver things and the p.o. rounded/stripped them just enough that it wont bite at all... someone told me to try to chisel them around till they are loose... and im not having any luck there... any ideas?

 

[GateKeeper]

try to cut a slot in it ? use a dremel tool or a small grinder to cut the slot, maybe apply some heat to it as well

 

[7981GS]

As the japanese screws are so soft, simply take a phillips bit and drive it into the stripped screw with a hammer.
After it has cut deep new grooves, hit it with the hand impact driver and they will come right out.

I found a pic. I place the bit in a 5/16" socket with adapter socket and wack it with a big hammer.

Daniel

 

[Suzuki_Don]

Knock the screw head sideways with a drift and hammer and then try to unscrew it. Vicegrips, or whatever will grip the head of the screw.

 

[willie]

If you've got the time, I'd put a few drops of penetrant on the interface between the head and the mating surface. Personally, I go so far as to put a few drops on that area from time to time to make sure it doesn't go dry before giving it a good whack as described above. A few choice words prior to hitting it seems to help also.
Willie

 

[FiremanBob]

PB Blaster is your friend. Besides that, I agree with both the slot-cutting and Phillips-hammer reforming methods of getting a bite on that screw.

Also, remember that Japanese Phillips-head screws are a different design from the rest of the world. The slot is cut at a different angle. This means that the sides of a standard Phillips driver don't make full contact against the screw, which leads to the stripping. You can find JIS drivers for cheap on Amazon.

 

[7981GS]

Bob, if you smack the phillips bit with a hammer, the soft screw BECOMES a U.S. phillips.
No need to waste money on un-nessesary tools.
Often, just the smack will break the fastener loose and off they come...

Daniel

 

[chuck hahn]

I would try the cut a new slot with a dremel and use the flat bit in the impact. Heat the crap out of it and then give it a good hard solid smack.

EDIT::: If theres locktite on the screws, which there probably will be, heat each one and once it starts to loosen remove it and THEN move onto the next one. The heat will soften the locktite but if it cools too much it will reset itself.

 

[tatu]

Before you cut slots and chiseling, you could try firmly hitting the screw head flat with a hammer, dont go mad, you are trying to close up the stripped cross. when the cross is closed up you can take the impact driver bit and hammer it back into the head thereby making the screw fit the bit then without wiggling it all about refit the impact driver twist it and whack it with the hammer a good stiff wallop.
Always worked for me.
If the head is too far gone then chiseling it is the way to go just make sure you use the correct size chisel and it's sharp.

 

[koolaid_kid]

Be sure and replace them with stainless steel allen head screws so this won't happen again.

 

[TyFerris]

thanks for all your help ive done everything except the dremmil only because i do not have one... and i just seem to be making things worse... have tempted to take it to the suzuki shop and let them deal with it

 

[TyFerris]

this may make me sound/look really stupid but is there some kind of way to fill the holes and the hammer with a phillips head?

 

[daturat100r]

If all else fails drill off the head to seperate the parts then you will have the shank of the screw to work on.Get it really hot then try a pair of vice grips or even weld a larger nut to the stub and wind it out.One trick with taking out screws is to try and tighten them a little before undoing.Saves damaging the head of the screw

 

[FiremanBob]

Of course, I meant: Use JIS screwdrivers on the screws that aren't ruined in this and future service operations, so that they won't become ruined.

 

[twr1776]

#10 Today, 03:28 PM koolaid_kid Be sure and replace them with stainless steel allen head screws so this won't happen again.

And use lots of anti-sieze on the SS allens

I have also used LH drill bits with a reversable drill going slowly, the drill will "catch" to break the screw loose. Once you break the bond you can usually get a screwdriver or vise grip on the screw to remove it the rest of the way.

 

[TyFerris]

im defiantly replacing the, with allen or hex...

 

[chuck hahn]

You can take a hacksaw blade and cut slots in the heads as well..will take some time but it can be done. Someone you know must have a dremel you can borrow for an hr or so.

 

[Normk]

Heating is a problem with the rubber manifolds as they will be destroyed unless you are fortunate. There's really no subsitute for rapid heating to red hot when trying to loosen a steel fastner in aluminum.

Tapping to close the head is an old trick because it works well to both provide some new grip and to loosen the screw threads. You may wish to also dip the phillips screwdriver bit into valve lapping compound to increase the grip. An impact driver (sometimes called a hammer screwdriver) is a huge advantage in these circumstances.

Before you cut slots and chiseling, you could try firmly hitting the screw head flat with a hammer, dont go mad, you are trying to close up the stripped cross. when the cross is closed up you can take the impact driver bit and hammer it back into the head thereby making the screw fit the bit then without wiggling it all about refit the impact driver twist it and whack it with the hammer a good stiff wallop.
Always worked for me.
If the head is too far gone then chiseling it is the way to go just make sure you use the correct size chisel and it's sharp.

 

[daturat100r]

Heating is a problem with the rubber manifolds as they will be destroyed unless you are fortunate. There's really no subsitute for rapid heating to red hot when trying to loosen a steel fastner in aluminum.

large soldering iron can be a good way to dump in a lot of heat to a selected spot quickly

 

[bwringer]

... have tempted to take it to the suzuki shop and let them deal with it

That way lies only madness and ruin...

Besides, a cheapo Dremel-like tool costs maybe, what, $25? Taking the bike to a shop would cost you a couple hundred minimum, and they'll screw it up even worse.