Stripped a screw.....WTF - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 52 Old 10-02-2010, 12:04 PM Thread Starter
1st Gear
 
zombievader's Avatar
 
Join Date: Jun 2010
Location: Santa Monica
Posts: 57
Stripped a screw.....HELP

So I was going to add some brake fluid to the front master cylinder today. The first screw came out of the lid no problem, the second broke the tip off my screwdriver and then melted like butter under the second. This is the first time I attempted to take the lid off btw, I've only put about a thousand miles on the bike and was going to top off all the fluids today.

Any suggestions?

Most motorcycle problems are caused by the nut that connects the handlebars to the saddle. ~Author Unknown

Last edited by zombievader; 10-02-2010 at 12:42 PM.
zombievader is offline  
Sponsored Links
Advertisement
 
post #2 of 52 Old 10-02-2010, 01:12 PM
4th Gear
 
Spec's Avatar
 
Join Date: Apr 2010
Location: Gateway to Death Valley!
Posts: 1,928
Quote:
Originally Posted by zombievader View Post
So I was going to add some brake fluid to the front master cylinder today. The first screw came out of the lid no problem, the second broke the tip off my screwdriver and then melted like butter under the second. This is the first time I attempted to take the lid off btw, I've only put about a thousand miles on the bike and was going to top off all the fluids today.

Any suggestions?

OK 1st thing the master cylinder is made of cast metal (magnesium or aluminum) so you can break it, OK?

Get something like a small chisel with a sharp edge. Use one of ends of the phillips hole to place the chisel. Tap it and chase the chisel counterclockwise to turn the screw, make sense?

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
Spec is offline  
post #3 of 52 Old 10-02-2010, 01:40 PM
4th Gear
 
vatrader's Avatar
 
Join Date: Sep 2008
Location: Virginia
Posts: 1,263
Yes sir, I feel your pain. Those screws have been unanimously voted most likely to strip every year since 1984 when the KLR 600 came out. My first attempt would be with a size larger Phillips head screw driver. Set it in place, tap it with a hammer to set it. Attempt to break screw loose. Next step would be a small bladed standard screw driver, tapped with hammer to set it.

I have had luck tapping one of these torx drivers into the slot and getting it to break loose.





If that doesn't do it, dremel a slot for a standard screwdriver. I have turned them out with a small, sharp cold chisel. Careful with the hammer, that ain't an anvil under that screw!

Once you get it out, I would suggest a different replacement type screw. I use these, and have no trouble. Most Ace or other hardware stores.


******
ďmany a trip continues long after movement in time and space have ceasedĒ- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]
vatrader is offline  
 
post #4 of 52 Old 10-02-2010, 02:39 PM
4th Gear
 
flash's Avatar
 
Join Date: May 2008
Location: North Texas
Posts: 1,534
Send a message via Yahoo to flash
http://www.trossenrobotics.com/store...river-Set.aspx

Gray-haired riders donít get that way from pure luck.

Unknown
flash is offline  
post #5 of 52 Old 10-02-2010, 03:34 PM Thread Starter
1st Gear
 
zombievader's Avatar
 
Join Date: Jun 2010
Location: Santa Monica
Posts: 57
thanks guys.


Edit; I just took it down to the dealer to see if they could do a quick fix.......they could, the mechanic took care of it in 5 mins. I slipped him a 20 and went on my way.

Most motorcycle problems are caused by the nut that connects the handlebars to the saddle. ~Author Unknown

Last edited by zombievader; 10-02-2010 at 05:20 PM.
zombievader is offline  
post #6 of 52 Old 10-02-2010, 05:18 PM
4th Gear
 
Buildit's Avatar
 
Join Date: Oct 2006
Location: London, Ohio
Posts: 1,123
I had the same thing happen, thank God I had a hand impact driver to extract the screw.

*** KLR650, Tweeting long before your kids thought it was cool.

ADVFilmer videos of trails, reviews and other dual sport related stuff. http://www.youtube.com/user/advfilmer
Buildit is offline  
post #7 of 52 Old 10-02-2010, 07:40 PM
1st Gear
 
Join Date: Sep 2010
Location: Pittsburgh, Pa
Posts: 25
Used a torsion impact driver with the same results.
klr_rider is offline  
post #8 of 52 Old 10-02-2010, 08:12 PM
Moderator
 
klr4evr's Avatar
 
Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
Posts: 3,548
Garage
Send a message via Skype™ to klr4evr
Get rid of the philips head screws. I replaced mine with allan head stainless. Same goes for the screws in the mirror bracket. You'll strip them too.

Phillips screws have got to be the worst invention by mankind.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
klr4evr is offline  
post #9 of 52 Old 10-03-2010, 09:47 PM
4th Gear
 
Spec's Avatar
 
Join Date: Apr 2010
Location: Gateway to Death Valley!
Posts: 1,928
Quote:
Originally Posted by klr4evr View Post
Get rid of the philips head screws. I replaced mine with allan head stainless. Same goes for the screws in the mirror bracket. You'll strip them too.

Phillips screws have got to be the worst invention by mankind.

The phillips screws on Japanese bikes are different than American and Euro phillips. American screwdivers tend to strip them out.

Japanese Phillips Screws

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
Spec is offline  
post #10 of 52 Old 10-03-2010, 10:04 PM
1st Gear
 
Join Date: Sep 2010
Location: Pittsburgh, Pa
Posts: 25
I replaced all mine with allen head stainless.
klr_rider is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Picked her up, stripped her down and kicked her out... fjteal Show Off Your Bike 2 10-13-2009 09:22 PM
Stripped Oil Drain Plug PTZ 1987 to 2007 Wrenching & Mods 25 01-11-2009 02:48 PM
Stripped! Lockjaw 2008+ KLR650 Wrenching & Mod Questions 18 01-05-2009 07:44 PM
Stripped footpeg bolt coachz 1987 to 2007 Wrenching & Mods 14 05-09-2008 02:41 AM
STRIPPED DOO THREAD-Help willows 1987 to 2007 Wrenching & Mods 8 11-30-2007 08:28 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome