Oil cooler cover change - stripped screw

[RavenWire]

Trying to swap the oil cooler cover for a beowulf one and somehow managed to strip the screw. Any ideas on the best way to remove it? Tried putting a piece of fabric between the screwdriver and screw, can get some traction but won't budge

[Sid Squid]

If it's that stuck it will probably require drilling out. Being a small bolt in an assembly made from relatively soft materials, it would be unwise to start doing anything brutal and risk damaging the cooler.

Also be assured you're not alone in finding this bolt stuck - it's right in the stream of water and road crud from the front wheel, when I ever find one that isn't stuck it's a real surprise.

[RavenWire]

My other option is to cut a notch on the top of the screw and see if i can get it moved with a flathead. Is it easy enough to do with a drill iif it comes to it?

[wideguy]

I'd try a light impact driver, perhaps some valve grinding compound on the driver bit/screw head for extra grip.

[timwilky]

+1 on the grinding paste

[Sid Squid]

It's a small soft screw that is properly corrosion welded in place - they always are - if you can grip the screw well enough to turn it worth a damn you'll twist the head off. Drill the head off and carefully remove the guard, then drill right through the rest of the screw and replace with suitable nut and bolt.

[mrs t]

hey i did exactly the same the other day swopping mine for a beowulf as well, had to drill it out, but all well now and a nice new shiny rad and oil cooler guards fitted :)

[Toooldtodie]

Wish I'd checked here first!
My cooler guard rusted to nothing (must be lying on an A road somewhere) and I could not remove said screw.
Have had to cable tie the rather lovely Evotech replacement over it as it had corrosion-welded itself despite a weeks worth of daily WD40 spraying. Should have known it wouldn't be that simple.
Not pretty, but stops me having to replace the cooler in the long run.. I hope.
Any ideas what's going to rot next so I can start budgeting?!

[Bibio]

its a suzuki, everything so get some ACF-50.

btw for those stubborn screws get a proper JIS screwdriver. yes they are expensive for a screwdriver but trust me when you do need it you will be glad you have it.

[Corny Gizmo]

Apologies for the resurrection... I too have rounded the oil guard retaining screw, also one of the radiator guard screws. Anyone know where I can buy these?

[maviczap]

According to the Alpha sport parts fiche its this part number for the 2005 Sv

02142-0510B

According to Robinsons Foundry its the same screw used in GSXR1000 tail light assembly

http://www.robinsonsfoundry.co.uk/content/pages/shop/parts/Suzuki/GSX-R/GSX-R1000/K2%202002/gsxr1000k2rearlight/1.htm

But I'd buy a button headed bolt/screw in stainless steel on ebay or elsewhere, as its getting all the **** from the from wheel hit it

[tom_e]

Definitely try and find out the size and just pick up some SS ones from eBay you'll get 4 or 5 for just over a quid.
Same with the radiator guard, I bought a pack of SS button head bolts from eBay and replaced the lot.

To be honest there aren't many bolts or screws left on my SK5 that aren't SS or Ti now.

[Corny Gizmo]

Thanks for the help guys, I have found the following two kits that look like they have what I need. Pro bolt dont have them listed...

Radiator kit - http://www.ebay.co.uk/itm/Suzuki-SV650-Stainless-Radiator-Bolts-Kit-/252168673704?hash=item3ab66c99a8:g:b34AAOSwvt1WRQO D

Oil cooler, tank mount and chain guard kit - http://www.ebay.co.uk/itm/Suzuki-SV650-Stainless-Oil-Cooler-Chain-Guard-Tank-Mount-Bolts-Kit-/262139901083?hash=item3d08c1749b:g:48UAAOSw7hRWQ6-q

[maviczap]

Just the job

[Toooldtodie]

Sad, but true. Every OE fastener I manage to remove pretty much gets replaced with something more corrosion resistant ss or anodised alu.

[Corny Gizmo]

I have ordered the two kits above, ill let you guys know what they are like :)

[tom_e]

I use a mix of Pro bolt and Titan classics for more specialised bolts and fittings then just for general bits and bobs I just buy bags of SS bolts off one of the fastener sellers on eBay.

[bigup]

Suffering the same problem.

Only fix to drill out ?

Anyone know what the size drill bit I'd need to use ?