Wilsons Sandbox

Posted: **Mon Mar 21, 2005 5:47 am**

Tried adding a little front brake fluid to my A19 and immediately stripped one of the two screws holding down the cover. True, I was in a little bit of a hurry to get back on the bike and ride in nice weather, but that screw stripped like it was made of wax. Now I guess it has to be drilled out? Risk of metal shavings dropping into the resevoir? Its stripped smooth at this point.

Posted: **Mon Mar 21, 2005 10:01 am**

At 11:46 AM +0000 3/21/05, klr250not wrote:

>Tried adding a little front brake fluid to my A19 and immediately >stripped one of the two screws holding down the cover. True, I was >in a little bit of a hurry to get back on the bike and ride in nice >weather, but that screw stripped like it was made of wax. Now I >guess it has to be drilled out? Risk of metal shavings dropping >into the resevoir? Its stripped smooth at this point.

Cut a slot in it with a worn-down (smaller radius to minimize any groovage to the cover) Dremel cutting disc. Then extract it with a screwdriver. No big deal if the slot gets cut a little into the cover, it's just cosmetic damage. Mark

Posted: **Mon Mar 21, 2005 11:50 am**

When I read on this list that those are made of "cheese" I went and bought SS hex socket replacements (for my brand new '04...). One came out nice'n'easy. The other stripped like yours, so I carefully drilled into the center and used a small EZout to remove it, so I replaced them on my other bike (Suzuki) too. The 6 on the Bandit came out nice'n'easy so there's DEFINATELY difference in quality! Ed --- In DSN_KLR650@yahoogroups.com, "klr250not" wrote:

> > Tried adding a little front brake fluid to my A19 and immediately > stripped one of the two screws holding down the cover. True, I was > in a little bit of a hurry to get back on the bike and ride in nice > weather, but that screw stripped like it was made of wax. Now I > guess it has to be drilled out? Risk of metal shavings dropping > into the resevoir? Its stripped smooth at this point.

Posted: **Mon Mar 21, 2005 12:12 pm**

Hello Ed, I was a metalsmith in the Navy and had to remove thousands of screws on aircraft. One of the best techniques I learned in the Navy, was to try tightening the screw ever so slightly, before you try removing it. In most cases this will break the set on the screw and allow the screw to be removed easily. Mike -----Original Message----- From: fasteddiecopeman [mailto:fasteddiecopeman@...] Sent: Monday, March 21, 2005 12:50 PM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Re: Stripped Screw When I read on this list that those are made of "cheese" I went and bought SS hex socket replacements (for my brand new '04...). One came out nice'n'easy. The other stripped like yours, so I carefully drilled into the center and used a small EZout to remove it, so I replaced them on my other bike (Suzuki) too. The 6 on the Bandit came out nice'n'easy so there's DEFINATELY difference in quality! Ed --- In DSN_KLR650@yahoogroups.com, "klr250not" wrote:

> > Tried adding a little front brake fluid to my A19 and immediately > stripped one of the two screws holding down the cover. True, I was > in a little bit of a hurry to get back on the bike and ride in nice > weather, but that screw stripped like it was made of wax. Now I > guess it has to be drilled out? Risk of metal shavings dropping > into the resevoir? Its stripped smooth at this point.

Archive Quicksearch at: http://www.angelfire.com/ut/moab/klr650_data_search.html List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Yahoo! Groups Links

Posted: **Mon Mar 21, 2005 2:06 pm**

KLR250not, Not sure but I think you're talking about the threads in the reservoir being stripped. If so it seems to me you can probably put the master cylinder in a horizontal orientation and then wipe the top sealing edge dry. Cover the reservoir with tape and then only work on the stripped screw. I'm guessing you can probably very easily go to a slightly larger diameter screw without problems. Just make sure the hole is deep enough for the tap and for darn sure keep the tap straight. I'm guessing it's a 10 minute job when you have the needed materials on hand. If you were talking about the screw head being stripped I think the dremel tool to cut a slot, mentioned in an earlier post is the way to go. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT

Posted: **Mon Mar 21, 2005 3:57 pm**

Its the screwhead so I'll go with the Dremel approach (tomorrow). Good tip from Tengai Mark I think it was. --------------------

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > KLR250not, > > Not sure but I think you're talking about the threads in the reservoir > being stripped. If so it seems to me you can probably put the master > cylinder in a horizontal orientation and then wipe the top sealing edge > dry. Cover the reservoir with tape and then only work on the stripped > screw. I'm guessing you can probably very easily go to a slightly larger > diameter screw without problems. Just make sure the hole is deep enough > for the tap and for darn sure keep the tap straight. I'm guessing it's a > 10 minute job when you have the needed materials on hand. > > If you were talking about the screw head being stripped I think the > dremel tool to cut a slot, mentioned in an earlier post is the way to go. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650, 79 R100RT

Posted: **Mon Mar 21, 2005 7:01 pm**

Sears also sells screw extractors, look kinda like a left hand thread drill, but only has the cutter tips to bite in and back out that screw. Never tried them, just noticed them in a flyer they sent me. Dooden A15 Green Ape (I backed mine out when it was new and added some anti-sieze to the threads, so hope when its time they come out) --- In DSN_KLR650@yahoogroups.com, Tengai Mark Van Horn wrote:

> At 11:46 AM +0000 3/21/05, klr250not wrote: > >Tried adding a little front brake fluid to my A19 and immediately > >stripped one of the two screws holding down the cover. True, I was > >in a little bit of a hurry to get back on the bike and ride in nice > >weather, but that screw stripped like it was made of wax. Now I > >guess it has to be drilled out? Risk of metal shavings dropping > >into the resevoir? Its stripped smooth at this point. > > Cut a slot in it with a worn-down (smaller radius to minimize any > groovage to the cover) Dremel cutting disc. Then extract it with a > screwdriver. No big deal if the slot gets cut a little into the > cover, it's just cosmetic damage. > > Mark

Posted: **Mon Mar 21, 2005 7:20 pm**

I've tried those Sears thing twice, crap! Riley A15 Montreal

----- Original Message ----- From: "Dooden" To: DSN_KLR650@yahoogroups.com> Sent: Monday, March 21, 2005 8:00 PM Subject: [DSN_KLR650] Re: Stripped Screw > > > Sears also sells screw extractors, look kinda like a left hand thread > drill, but only has the cutter tips to bite in and back out that screw. > > Never tried them, just noticed them in a flyer they sent me. > > Dooden > A15 Green Ape > > (I backed mine out when it was new and added some anti-sieze to the > threads, so hope when its time they come out) > > > > --- In DSN_KLR650@yahoogroups.com, Tengai Mark Van Horn > wrote: >> At 11:46 AM +0000 3/21/05, klr250not wrote: >> >Tried adding a little front brake fluid to my A19 and immediately >> >stripped one of the two screws holding down the cover. True, I was >> >in a little bit of a hurry to get back on the bike and ride in nice >> >weather, but that screw stripped like it was made of wax. Now I >> >guess it has to be drilled out? Risk of metal shavings dropping >> >into the resevoir? Its stripped smooth at this point. >> >> Cut a slot in it with a worn-down (smaller radius to minimize any >> groovage to the cover) Dremel cutting disc. Then extract it with a >> screwdriver. No big deal if the slot gets cut a little into the >> cover, it's just cosmetic damage. >> >> Mark > > > > > > Archive Quicksearch at: > http://www.angelfire.com/ut/moab/klr650_data_search.html > List sponsored by Dual Sport News at: www.dualsportnews.com > List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > > > Yahoo! Groups Links > > > > > > >

Posted: **Mon Mar 21, 2005 8:09 pm**

I too have tried those Sears things and yes, they are crap. Joe Grove

Posted: **Mon Mar 21, 2005 9:01 pm**

In a message dated 3/21/2005 8:11:34 AM Pacific Standard Time, tengai650@... writes: Cut a slot in it with a worn-down (smaller radius to minimize any groovage to the cover) Dremel cutting disc. Then extract it with a screwdriver. No big deal if the slot gets cut a little into the cover, it's just cosmetic damage. A good reason to keep a selection of worn down, but still good cutting discs. I've used this trick on many stripped out phillips screw heads. Pat G'ville, NV [Non-text portions of this message have been removed]

Wilsons Sandbox

dsn_klr650 lowered klr

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