Stripped clutch-oil-resivor-cover screw head.. help!

[Ooobah-Moto]

So I stripped the head (not the thread) on the of the screw that holds down the clutch oil resivor. What now?!

[uk_mouse]

Try and tap the screw round using a fine centre punch, perhaps?

You could try clamping the reservoir lid down in some way (maybe a large elastic band would do?) - this might relieve the pressure on the screw caused by the compression of the rubber diaphragm in the reservoir. If the other lid screw is already out, put it back in for the same reason.

Only ideas I'm afraid, but probably worth a try.

[Ooobah-Moto]

Originally Posted by uk_mouse

Try and tap the screw round using a fine centre punch, perhaps?

You could try clamping the reservoir lid down in some way (maybe a large elastic band would do?) - this might relieve the pressure on the screw caused by the compression of the rubber diaphragm in the reservoir. If the other lid screw is already out, put it back in for the same reason.

Only ideas I'm afraid, but probably worth a try.

UK_MOUSE, thanks for the advice; however, I'm affraid I tried that... screwed the other one back in - quite tight - and still nothing. Although, I've yet to try clamping down the "plate" and unscrewing it. Problem is, I reefed on it so much that there's NOTHING left of the original head - pretty much an aluminum ice cream cone now! STUPID ME - I KNOW!!



Well, good excuse to do away with the old and farkle with new!
So, I think I'll order the flashy orange OEM KTM clutch reservoir plate - in which case, I'll grind the original plate + screw head down until I can pull it off by hand - a crude crude solution indeed! (unless anyone has futher suggestions?!).

.....as a second to last resort, I'll try creating a philips head first (with a Dremel - even if that means cutting into the plate a little).... there might be enough material left there to latch on to.

[cpmodem]

Sounds like a job made for the Craftsman power extractor. I don't sell 'em, just use 'em. Work good, especially on small screws with stripped heads.

[ABYSS]

this is gonna sound scary but we do it on aircraft all the time and it is completely safe.

Get a drill bit the diameter of the screw. Chuck it in a hand drill and place in the center of the screw head. (This will be be centered if you rounded it out) Now you drill but only bump it a turn revoluition or two at a time two. Once you get threw the screw head with the drill bit still in the drill but not rotating rock the drill bit back and fourth. This will snap the head off then pull of the cover and remove the stud with a pair of vise grips.

This is VERY easy the whole trick is to go slow, straight and only threw the head of the screw. You can check you depth buy using the other screw for measurment purposes.

Believe me once you do this 500 or 1000 times on a plane it is nothing. But it is a very fast way to remove a screw safley and without damaging anything else.

[Footprint]

http://www.sears.com/shc/s/p_10153_12605_00953153000P

[Steve1100gs]

Originally Posted by ABYSS

Believe me once you do this 500 or 1000 times on a plane it is nothing.

I do believe you.
it just made me laugh the way you said it's nothing once you've done it 1000 times.


A dremel might help remove the head and then get pliers on the stud.???