Cant unscrew a stuck screw, even with a impact screw driver and WD-40. Can anyone help?

Question

I need to replace the rubber and plastic part of my throttle on my motorcycle. But I cant take off the bar-ends in order to switch it out. Ive tried using a electric drill, and a impact screwdriver, but nothing is working. The threads are starting to get damaged because i tried so much.


Anyone have any suggestions? I need to remove the barends so I can hook the throttle cables on to it. I have a 1999 500R Ninja if it matters.

When I mean thread, I mean the head of the thread, where screwdriver locks in to turn. The threads arn't totally ruined yet, I didn't want to keep trying to ruin them even more. Hopefully I can reuse the old screw, instead of having buy a new one.

I havnt tried the heat trick yet, but Ill do it today and see how it goes. Thanks for all the replies so far.

I got the screw undone!!! Heat worked. I did not realize that they used red loctite on there. Thanks guys!! I wish i could give you all best answers

Answer 1

try using a left handed drill bit, sometimes you can pound in a torx socket into the screw, you can also try to pound/grind a slot and use a standard screwdriver

Answer 2

First you'll want to verify that the threads are right-handed. Next, if the head is still on the screw it will help maintain center when drilling for an E-Z out which is the most important factor to consider when drilling a screw. If the head is already removed, you'll want to use a center punch to mark the center of the screw and provide a starting point for the drill bit. Then choose a drill bit that is smaller than the screw diameter which is probably around 1/4" and drill the screw at least 1/4" deep. Tap the largest E-Z out that will fit into the hole you drilled while trying to turn the screw out. Don't force it if it doesn't turn because you'll break the E-Z out, then you're up poop creek without a shovel. If the screw doesn't back out, you'll have to drill the entire screw out and replace the bar end. If the screw is left-handed, the typical E-Z out set will do no good and you may as well go straight to drilling the screw out.

Answer 3

First, I want ot repeat something one or two of the others said, and add a bit. NEVER try an eas-out to get a stuck screw out of steel or aluminum. About 95% of the time, at least, you wind up with a broken eas-out to get out, as well as the broken bolt. If possible, drill the head off, with a bit just slightly larger than the bolt. Then with a stud puller, or a good pair of visegrips, get the end of the bolt, and turn it out. If it does not protrude enough for this, drill as straight as possible down the boltl with a drill which is the tap-drill size for the bolt. Then likely you can pick the threads out with a sharp awl, or worse case, run a tap down the hole. OR find a machine shop who will get it out for you.

Tomcotexas

Answer 4

Are the threads stripped? Or is it the screw head? If it is the screw thread you can get a set or 'easy outs' from sears for $20. Basically with the easy outs you drill into the screw then tap in the easy out which is reverse threaded so when you go to loosen the screw the easy out bites into the screw and you are then able to remove it.

Answer 5

Other than what others have answered, the only suggestion I can offer is try a propane torch. An Oxy/Acetylene would be too hot.
Heat the screw (we're not looking for red hot here, just hot enough so you can't touch it). Let it cool down. Heat the area around the screw. While hot, try loosening. This SHOULD break the rust loose that is holding it.

Answer 6

I find a propane torch to be very helpful on a locked bolt. Never had that issue on a screw before, though. Just heat it up for about 20 seconds, then let it sit for a minute. The heat does something, not sure. Makes things expand and shrink and whatnot; maybe it does something to locktite, too. I have used this trick quite a bit when working on my car.

Answer 7

Those screws are installed at the factory with Locktite.
It takes a lot of force to break them loose.
If a handheld impact wrench isn't used properly, they won't come out.
Don't use any turning motion, press the impact wrench to the collapsed position and slam it a few times with a metal hammer.
The shock will help to break free the Locktite and the phillips bit will seat better in the screw, giving it a better grab.
Then use the impact wrench as normal.
Next solution would be to use an air impact wrench.
Ride it to a shop and they'll do it on the spot, or bring your bike to your regular auto repair shop that know you and they'll remove it with their tools.

An Easy Out will not work in this situation.
Last resort - drill the screw until the head falls off.
The bar end will slide off.
Dig the rubber dampener out with a pocket knife - it won't be difficult.

Answer 8

You might try tapping the centet of the screw with a center punch and a hammer this impact will help break loose the threads at times. If is possible heat may be applied also causing the expansion and contraction to loosen threads but I think rapping it with center punch will loosen it.

Answer 9

Since it is not unscrewing and the threads are getting damaged, you need to use a screw extractor. The screw extractor looks like a drill bit with threads, but in reverse direction. You will drill a small hole in the center of the screw. Insert the screw extractor with your electric drill and it will imbed itself into the screw and then remove the screw. The screw exctractor looks like a drill with threads, but in reverse direction. You will then need a replacement screw.

Answer 10

You could try using a grinder to cut a slot in the screw, which would make it a flat head screw. Then use the largest flat head screw driver that will fit in the slot to unscrew it.