SuzukiSavage.com - How the $#%&! do you get the screws out...

DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: How the $#%&! do you get the screws out... Reply #15 - 06/06/09 at 19:32:31 This image isn't too bad... Click for full size: It looks like the bundle of wires and clutch cable got moved around. -D. Dwarf
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Savage_Amusement Serious Thumper Offline On this steel horse I ride. Posts: 1004 Omaha, NE Gender:	Re: How the $#%&! do you get the screws out... Reply #16 - 06/06/09 at 22:59:17 One thing that drive me nuts about this bike is the clutch is on the left hand, but on the right side of the bike. The throttle is on the right hand but left side of the bike.... HELLO.
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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: How the $#%&! do you get the screws out... Reply #17 - 06/07/09 at 06:35:22 A new day! First, waffles. Second, S40. Today's first challenge will be the timing inspection cover. Wish me luck! -D. Dwarf
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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: How the $#%&! do you get the screws out... Reply #18 - 06/07/09 at 07:46:10 King Kong must have been working the day my S40 was assembled. A few bent tools and scratched up timing inspection cover and no luck. Maybe it's time to grind down an old spade bit. (no used brake pads available) -D. Dwarf
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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: How the $#%&! do you get the screws out... Reply #19 - 06/07/09 at 08:30:44 Educatedredneck - I owe you a 6 pack. Grinding down a scraper made the perfect tool. Items removed: 1 Items damaged: 1 Batting 1000. -D. Dwarf
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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: How the $#%&! do you get the screws out... Reply #20 - 06/07/09 at 10:39:02 I was going to replace the valve inspection cover bolts, but no local store has them in stainless. Would using standard zinc coated be acceptable or should I hold off until I can find the correct ones? -D. Dwarf
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28674 Tucson Az Gender:	Re: How the $#%&! do you get the screws out... Reply #21 - 06/07/09 at 10:56:52 Those bolts don't torque down very much. I don't think you need stainless....
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Savage_Amusement Serious Thumper Offline On this steel horse I ride. Posts: 1004 Omaha, NE Gender:	Re: How the $#%&! do you get the screws out... Reply #22 - 06/07/09 at 11:20:56 They don't have metric stainless? You can put any style of head on it that you want. I go with Allen because it allows me to carry less tools. You can have carriage, standard, Phillips, what ever there is. If you order the kit off of ebay you will get all stainless. It is a nice kit, comes with a few extra.
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DrunkenDwarf

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Morning Zombie

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Seattle, WA
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Re: How the $#%&! do you get the screws out...
Reply #23 - 06/07/09 at 12:57:27

Finally some progress.

Had a minor set back when I realized I didn't have the right socket for the spark plug, then bought the wrong one, finally got the right one.

Got all the bolts out of the head cover except for the middle one. My 10mm wrench is a piece of crap and I'm concerned I'm going to round it off before it comes loose. There's no room for a socket.

I'm definitely beginning to question the wisdom of my actions. Grin

-D. Dwarf

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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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DrunkenDwarf

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Morning Zombie

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Re: How the $#%&! do you get the screws out...
Reply #24 - 06/07/09 at 12:59:06

Savage_Amusement wrote on 06/07/09 at 11:20:56:

They don't have metric stainless? You can put any style of head on it that you want. I go with Allen because it allows me to carry less tools. You can have carriage, standard, Phillips, what ever there is.

If you order the kit off of ebay you will get all stainless. It is a nice kit, comes with a few extra.

They do, just not in that head style. Maybe I'll go back and see what my options are.

If I ever have to do this again (dreading) I may order that kit.

-D. Dwarf

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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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Digger

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2005 No Login

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Ya gotta be tough to
ride singles!

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Colorado Springs, CO
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Re: How the $#%&! do you get the screws out...
Reply #25 - 07/02/09 at 20:34:30

DrunkenDwarf wrote on 06/06/09 at 11:37:17:

...of the top of the carb?

-Frustrated Dwarf

Any time you see what looks to be a Phillips-head screw with a small dot embossed near the cross slots, you will need a JIS (Japanese) Phillips screwdriver.

Here is where I got mine:

JIS Phillips Screwdrivers

Not very expensive at all, especially considering the headaches they'll prevent.

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Digger
2001, Metallic Glacial Blue, Raptor Petcock, Verslavy (first hole) (otherwise, mechanically, the bike is stock), 13,xxx miles
I don't own a cage.
www.astronautbiker.com

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Boule’tard Serious Thumper ModSquad Offline Master of the Obvious Posts: 1620 Austin TX Gender:	Re: How the $#%&! do you get the screws out... Reply #26 - 07/02/09 at 20:41:36 Digger wrote on 07/02/09 at 20:34:30: Here is where I got mine: JIS Phillips Screwdrivers Not very expensive at all, especially considering the headaches they'll prevent. 4-6 bucks? How's the metal on those things?
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Educatedredneck

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Sometimes it's
better to be lucky
than good.

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Hampstead, Maryland
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Re: How the $#%&! do you get the screws out...
Reply #27 - 07/02/09 at 22:36:12

DD, Glad to hear that my scraper-screwdriver idea worked for you. I drink St. Pauli Girl!!!! Wink

I have made the habit of when I remove a JIS phillps screw off my savage, I take the time and get an allen head to replace it, especially if I know I'm gonna be back at that area again. I HATE rounded screws.

Keep at it DD, wrenchin and learnin is half the fun!!! Grin

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1997 Savage - Hard Chrome Drag Pipe, Seat Mod, 152.5 main, 1 - #4 washer, Di Hard Battery, T-Kat, 1" Drag Bar

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Digger

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2005 No Login

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Ya gotta be tough to
ride singles!

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Colorado Springs, CO
Gender: male

Re: How the $#%&! do you get the screws out...
Reply #28 - 07/07/09 at 21:18:23

Boule’tard wrote on 07/02/09 at 20:41:36:

Digger wrote on 07/02/09 at 20:34:30:

Here is where I got mine:

JIS Phillips Screwdrivers

Not very expensive at all, especially considering the headaches they'll prevent.

4-6 bucks? How's the metal on those things?

Harder than the metal the screws are made from....and that's good enough! Wink

Actually, FWIW, the screwdrivers are made in Germany and seem to be of pretty decent quality.

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Digger
2001, Metallic Glacial Blue, Raptor Petcock, Verslavy (first hole) (otherwise, mechanically, the bike is stock), 13,xxx miles
I don't own a cage.
www.astronautbiker.com

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voldigicam

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SuzukiSavage.com
Rocks!

Posts: 327

Re: How the $#%&! do you get the screws out...
Reply #29 - 07/15/09 at 17:09:57

An excellent technique not mentioned above:

Use a really good punch. Not a sears one. Strong steel. Gunsmith quality. Need a really good clean edge. With bracing, can get just that little bite and tap the screw loose enough to be finished with a screwdriver. Two of mine only loosened this way. Bracing has to be perfect.

I'm thinking on a cam cover fastner now - it's pretty well stuck. I may cut the head off to leave the shaft, then I have something to work with and might not need to drill out a broken fastner!

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2007 S40
2003 Volusia 40th Ann.
Friendsville, TN

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