Worn screws/bolts, how to remove?

N

Neko

New Member
Hello there! New guy here saying hello from sunny Costa Rica

I have been reading a lot of threads on the forum, but the amount of topics is just huge!

About three weeks ago my grandfather gave me his 1980 GS450 suzuki, which has been sitting in his garage for some years now. All in all it has a little over 12 k miles on it, and after a short visit to the mechanic (carboureator and air filter needed some serious cleaning and oil change) I rode it back home. It runs as good as the first time he took me for a ride on it.
Thing is, yesterday the clutch cable snapped on the handle, I researched the net on how to change it, but when I got home I found that the screws/bolts that hold the plate over the other end are quite worn down and I have not been able to remove a single one

Can anyone point out a thread were I can read about how to resolve this, or maybe someone share any ideas?

Cheers
 
there are many ways to remove such screws....

i usually use some ice spray (freezes the bolt and has some wd40 lube in it) and then i.smack ut with my impact driver.

if the philipps head is worn out you can use a dremel either to rework the slits for the impact or you can flatten the round head on 2 points to use a tool to grab it and spin it.

sometimes heat cycles help too.use a little storm lighter to heat then cold spray...again...again.

then use impact.
 
Thank you Ryan,

I was thinking on using the dremel but wasn't sure on how to tackle the lower half ones which are kindda "sunk" in the plate. I can't figure out how to do it without actually cutting into the plate itself.

But will definetly start working on the other ones.

Again thanks for replying
 
Neko said:
Thank you Ryan,

I was thinking on using the dremel but wasn't sure on how to tackle the lower half ones which are kindda "sunk" in the plate. I can't figure out how to do it without actually cutting into the plate itself.

But will definetly start working on the other ones.

Again thanks for replying
Click to expand...

youre welcome.

post pics.cant really figure out what you mean.
 
thump_2207998image.jpg


Here it is, if we look at it as a clock, I'am going to have problems with the one at 3 o'clock
 
I recommend drilling a little into the head of the bolt and then hammering a Phillips head into it VERY hard and then trying to twist it out. Same principle as an impact driver really. That's how I got most of my clutch cover bolts out
 
Neko said:
thump_2207998image.jpg


Here it is, if we look at it as a clock, I'am going to have problems with the one at 3 o'clock
Click to expand...

before you drill or do anything with the head be sure to remove the contact rust between the screw thread and the motor block thread.

when the head is fucked up or braks,youre fucked.

so start with cold and heat cycles.

use an impact with a rubber hammer with a really wide angled philipps,use a dremel to widen and deepen the philipps slits.
 
It doesn't look like you're going to get a dremel into the recess on #3. Nor vise grips. Someone makes a gritty paste specifically for this purpose. You put a dab of it on the screw head and it gives you better gripping power.

Another option is to use a cold chisel and hammer on it a few times, then try to get a slotted screw driver in the groove.

If you drill out a little bit of it, an easy out might do the trick too.
 
Um, those aren't Philips bolts, they're JIS, (Japanese Industrial Standard). Got a flatter recess where the Philips are pointy.

Using a Philips bit is just begging to strip them out. Even with the right screwdrivers they're a bitch. Once you've ruined them, though, an impact driver is your friend.
 
Killman77 said:
Um, those aren't Philips bolts, they're JIS, (Japanese Industrial Standard). Got a flatter recess where the Philips are pointy.

Using a Philips bit is just begging to strip them out. Even with the right screwdrivers they're a bitch. Once you've ruined them, though, an impact driver is your friend.
Click to expand...

just restoring a Yam RD...only screws like that.

the impact will work with the widest philipps....one just needs to enlargen the slits for the bit...and then it will will just SLIP out. :-)
 
Killman77 said:
Um, those aren't Philips bolts, they're JIS, (Japanese Industrial Standard). Got a flatter recess where the Philips are pointy.

Using a Philips bit is just begging to strip them out. Even with the right screwdrivers they're a bitch. Once you've ruined them, though, an impact driver is your friend.
Click to expand...

Hence the use of the larger philips bit in the impact driver kit, which has a flat recess.
Trust me I have removed hundreds and hundreds of them without issue.
An impact bit made for JIS fasteners would be better but I don't have one.
 
Just a heads up, the impact driver doesn't always save the day. I've removed tons of stuck screws off Japanese bikes with an impact driver but was bested by those same exact sprocket cover screws on my '81 GS450. I used the largest, best fitting bits I had, used a rubber mallet, the whole deal, and I stripped every single one. So, I chucked up a left-handed drill bit into my drill, center punched the screws and drilled them all out in about five minutes.
 
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