Clutch reservoir screws frozen - what'd I do wrong? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 7 Old 05-08-2009, 12:29 AM Thread Starter
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Clutch reservoir screws frozen - what'd I do wrong?

I went out tonight to change the oil on my Vee - no problems there, beautiful evening, so I decide to bleed the clutch - I put on SS lines everywhere this spring, and the bike's been shifting kind of cranky, jumps on the shift to 1st from neutral, so I thought maybe there's some air in there and it's not disengaging all the way.

Get out my trusty phillips, try to remove the reservoir cover - no go. Careful now ... SH*T! Screw head is stripped. Try the other screw, also frozen tight, and end up stripping its head too. :bom_furious3: Off to the hardware store to get an extractor, STILL won't turn, neither of them. I work at it for half an hour or so, finally get one of them out, but the other simply will not move. Finally I give up and drill the head off. :mad: Thank goodness I've got my new-to-me SV to ride tomorrow.

What I don't get is: once I get the cover off, the body of the remaining screw just turns out with my fingers, smooth as silk. So somehow it was the head of the screw that was glued to the reservoir cover? I'm sure I didn't use an impact wrench to tighten the cover screws after doing the clutch line, no loctite either. Just to see, I loosened the brake cover, no problem at all. Maybe there was some residual brake fluid in the countersink, that acted like glue? Any ideas? What'd I do wrong?

Also: the Vee will have to sit with the reservoir cover duct-taped to the cylinder until I can get replacement screws. Since the seal is not so good, would you recommend replacing the fluid again once I can button her up?

Thanks, Jim

Silver '08 DL1000, '03 SV 650, '09 Yamaha R1 track bike, '13 Daytona 675r race bike
The lure of the racetrack was too much for me to resist ... the Vee has to find a new home.
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post #2 of 7 Old 05-08-2009, 11:37 AM
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This is very common. I used to always have a spare set of those crappy soft screws whenever I needed to open up the master cylinder. I've had to drill off the heads of screws too many times to count.

I've got a cheap impact screwdriver that works wonders on these things.

Keep in mind that most Japanese screws are not actual phillips heads but some other sort of screw that just looks like a phillips head (I think someone put up a guide on this here sometime ago). A phillips head screw doesn't actually fit exactly right and will strip out the screw. The proper screwdriver would be helpful.

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post #3 of 7 Old 05-08-2009, 12:01 PM
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I have two little tricks I use for those little buggers - and any similar pseudo-phillips screws. As soon as I feel resistance or see that the screwdriver is getting a grip, I try turning it tighter. If I'm going to strip an edge on the screw, at least it won't be the one that loosens it. A light shot with an impact driver toward tightening may break the rust holding the screw in place. If nothing happens, try a light shot towards loosening.

Then, for those little bugger reservoir screws, try turning it with a small, strong flathead screwdriver. Sometimes you'll get better grip on the screw surfaces than with a slippery phillips head screwdriver.

Those are my two cents on the subject anyway. I've thought about having some spares around, but I'm quite certain that at eleven o'clock at night when I'm doing this kind of thing, it is incredibly unlikely that I can remember where I so wisely stored them.

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post #4 of 7 Old 05-08-2009, 01:54 PM Thread Starter
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Quote:
Originally Posted by Bisbonian View Post
Keep in mind that most Japanese screws are not actual phillips heads but some other sort of screw that just looks like a phillips head (I think someone put up a guide on this here sometime ago). A phillips head screw doesn't actually fit exactly right and will strip out the screw. The proper screwdriver would be helpful.
Arrgh, didn't think about that. So I probably did overtighten them, and then just went to work with the wrong blade. Did some googling, here's everything I wanted to know about screws and more: http://en.wikipedia.org/wiki/Screw

Evidently they are called JIS crosspoint screws. Betcha it's not easy or cheap to find drivers or bits for them.

Thanks, Jim

Silver '08 DL1000, '03 SV 650, '09 Yamaha R1 track bike, '13 Daytona 675r race bike
The lure of the racetrack was too much for me to resist ... the Vee has to find a new home.
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post #5 of 7 Old 05-09-2009, 09:57 PM
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Quote:
Originally Posted by jsr1017 View Post
Betcha it's not easy or cheap to find drivers or bits for them.
I wonder if toolkit screwdriver is JIS?..
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post #6 of 7 Old 05-09-2009, 10:36 PM
 
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Here is a set.
http://www.etool.ca/RENDER/1/26/235/3483.html
Maybe just chang them to an allen head?
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post #7 of 7 Old 05-10-2009, 07:54 AM
 
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I've always used a large bit in a hand impact driver to tighten and loosen those screws. The big bits fit very snug and the large handle gives plenty of torque. HTH!
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