My Seat Screws are completely seized!

My Seat Screws are completely seized!
I was attempting a service on the SV650S that I purchased 2 weeks ago , on removing the black plastic panels I found that 2 of the screws holding the seat down are seized.
I managed to remove one of the screws and replace it with a new bolt from the Suzuki dealer but the other one will not budge. I can get no purchase on it as the head is badly chewed so I believe my only option is to drill the screw out and retap the thread.

Can anyone advise how to do this?
Am I correct in saying the screws holding the seat down are 6mm so drilling it out with a 5mm bit and then retaping is the best course of action?

That's a bit of a worry, because as far as I'm aware you can't get the tank up with the seat on, so you can't change the rear plug for starters. What year is bike Shadow?

My thought is that it's crossthreaded. Not uncommon on the seat screws.

Would an impact driver be any good. I would imagine that if it could be freed just a bit you might be able to get it out.
I have to say that when putting mine back in (K6) I never do them too tight, just a hand tight pinch. I don't think they need to be tight as they aren't going to fall ot because the side panels will stop them. They only need to stop the seat being lifted....

The bike is a 2000 model.

I was going to go out and purchase an impact drive kit but I am wonder how much use this will be as the head on the screw is almost gone.

The screws that are in there just now are Philips the ones the Suzuki dealer supplied me with are Alan key screws. So they may well be the wrong screws that have been put in there by the previous owner.

Are these what i am after?

http://cgi.ebay.co.uk/6MM-LEFT-HAND-...ayphotohosting

[timwilky]

They should be Allen headed machine screws.

Which side is it, be careful drilling as the loom runs behind the screw on the RHS, a well known chaffing point.


Note. Those taps are left hand thread. useful for something. But not for anything on an SV

Its on the Right Hand side.

And you are correct i can see the looms , pretty concerning to be honest!.

Originally Posted by TheShadow

The bike is a 2000 model.

The screws that are in there just now are Philips the ones the Suzuki dealer supplied me with are Alan key screws. So they may well be the wrong screws that have been put in there by the previous owner.

The OEM are indeed Allen Bolts. Not a good start to your ownership.

Maybe tapping the bolt head with a drift in an anti clockwise direction will start to shift it. Also if you push down on the seat as you try and undo it as the bolts are sometimes under tension.

have you not got a dremel you can use to cut a groove on the head then use a flat screw driver to get it off.

Can anyone confirm the screw size as 6mm?