Stuck brake resv. cover screws - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 20 (permalink) Old 05-26-2014, 12:53 PM Thread Starter
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Stuck brake resv. cover screws

Trying to service the brakes on the bike but I can't open the cover to add fluid. Screws are really stuck! I've torqued the shaft of one screwdriver and burred the head of one screw pretty bad by now. I'm about to go to the torch and do the heat/cool cycles and see if I can bust it loose without having to drill it out.

Anyone have any hints tips?
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post #2 of 20 (permalink) Old 05-26-2014, 01:05 PM
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get a good number 2 phillips head screw driver and hit it with a hammer while slowly turning the screw

do you have the round mc or the rectangle one ?

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post #3 of 20 (permalink) Old 05-26-2014, 01:59 PM Thread Starter
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Round. I have tried tapping it and even tried one of those hand held impact screwdrivers. Neither screw has budged.
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post #4 of 20 (permalink) Old 05-26-2014, 02:07 PM
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Don't take the torch to it. You'll end up messing up the rubber inside the mc. If you can't get them out withthe usual methods you might as well drill them or try a screw extractor kit.

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post #5 of 20 (permalink) Old 05-26-2014, 03:02 PM
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Usually a bit of Kroil or some other penetrating oil and an impact driver works, but if you have already damaged the heads you might have to drill the heads off, remove the cap, then maybe they can be backed out with pliers or something...JMO...
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post #6 of 20 (permalink) Old 05-26-2014, 03:16 PM
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I had the same issue, managed to break one with a 1/4 ratchet and LOTS of pressure, the second one I had to drill out
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post #7 of 20 (permalink) Old 05-26-2014, 03:24 PM
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I had the same situation and nothing worked except using a small automatic center punch to put a tiny dimple between the center hole (for the allen wrench or Phillips slot) and the outer edge of the head. Do this on a slight angle so that you can use a regular center punch in that dimple and tap it with a hammer to drive it in the proper direction for removal of the bolt. You do not need to go too deep with the dimple but just enough to get a good "footing" for the regular driving punch. I had tried six different penetrating oils, a hand held impact driver, Phillips head tip held tight with two clamps and a wrench on the tip shaft plus countless other methods I can't even remember right now. I replaced the screws with flat allen head socket screws and some never seize goop to avoid future problems. During my preseason bike check up I pop them out and dab a fresh blob on them again after a good cleaning. Good luck and take your time when attempting this initial removal.

and always remember, "Ride until you rot!"
**Really not sure if the Big "C" is back right now
but having to face the fact that this is a lifetime routine
going forward. Five operations done and it still continues.

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post #8 of 20 (permalink) Old 05-26-2014, 03:29 PM Thread Starter
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Gave in and got out the drill. Got lucky I think. Normally for me this turns into a long, drawn out affair involving lots of drill bits, dental picks, and usually retapping the hole.

Drilled just large enough to get the heads off. One side then unscrewed by hand, the other went with a little effort and small flatblade screwdriver. Off to get some replacements and will then probably celebrate my success and mechanical prowess with an adult beverage...

Thanks for the tip of not trying the torch. Looking at it I probably would have mucked up the seals and been off the road for a week or more!
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post #9 of 20 (permalink) Old 05-26-2014, 03:50 PM
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Quote:
Originally Posted by ArkTinkerer View Post
Gave in and got out the drill. Got lucky I think. Normally for me this turns into a long, drawn out affair involving lots of drill bits, dental picks, and usually retapping the hole.

Drilled just large enough to get the heads off. One side then unscrewed by hand, the other went with a little effort and small flatblade screwdriver. Off to get some replacements and will then probably celebrate my success and mechanical prowess with an adult beverage...

Thanks for the tip of not trying the torch. Looking at it I probably would have mucked up the seals and been off the road for a week or more!
glad you got it fixed

remember they dont have to be Hercules tight just snug when you put them back on

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Sucks getting old but it beats not getting old.

i got my helmet but it sure makes licking the windows a chore

cell phone number for anyone who needs it 214-516-1738

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post #10 of 20 (permalink) Old 05-26-2014, 04:00 PM
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Quote:
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Usually a bit of Kroil
I am going to guess, most here have never heard of Kroil.
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