Oil cooler cover change - stripped screw - SV650.org

01-12-13, 11:09 PM

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 · 02-12-13, 08:08 AM

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.

02-12-13, 09:04 AM

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?

02-12-13, 12:23 PM

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

timwilky · 02-12-13, 01:07 PM

+1 on the grinding paste

Sid Squid · 02-12-13, 01:47 PM

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.

03-12-13, 04:58 PM

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 · 04-07-15, 06:15 PM

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 · 04-07-15, 10:57 PM

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.

12-04-16, 09:50 AM

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?

01-12-13, 11:09 PM	#1
RavenWire Guest Posts: n/a	Oil cooler cover change - stripped screw 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

02-12-13, 08:08 AM	#2
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Oil cooler cover change - stripped screw 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. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

02-12-13, 09:04 AM	#3
RavenWire Guest Posts: n/a	Re: Oil cooler cover change - stripped screw 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?

02-12-13, 12:23 PM	#4
wideguy Guest Posts: n/a	Re: Oil cooler cover change - stripped screw I'd try a light impact driver, perhaps some valve grinding compound on the driver bit/screw head for extra grip.

02-12-13, 01:07 PM	#5
timwilky Member Mega Poster Join Date: Mar 2004 Location: Not in Yorkshire. (Thank God) Posts: 4,116	Re: Oil cooler cover change - stripped screw +1 on the grinding paste __________________ Not Grumpy, opinionated.

02-12-13, 01:47 PM	#6
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Oil cooler cover change - stripped screw 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. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

03-12-13, 04:58 PM	#7
mrs t Guest Posts: n/a	Re: Oil cooler cover change - stripped screw 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

04-07-15, 06:15 PM	#8
Toooldtodie Member Join Date: Jun 2012 Location: Chelmsford Posts: 410	Re: Oil cooler cover change - stripped screw 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?! __________________ Thought I was in a bad mood, but it's been 30 years now, so I suppose it's just who I am. 05 SV650s now with proper suspension, hurrah!

04-07-15, 10:57 PM	#9
Bibio Member Mega Poster Join Date: Jul 2008 Location: here as devil's advocate Posts: 11,540	Re: Oil cooler cover change - stripped screw 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.

12-04-16, 09:50 AM	#10
Corny Gizmo Guest Posts: n/a	Re: Oil cooler cover change - stripped screw 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?

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