Seized screw...what would you do?

[matsuba]

I started stripping the front end down on Sunday and was doing fine until it came to removing the clutch cable and lever. The screw was completely stuck and looked like someone had tried (and failed) to remove it before as the screw was all chewed up. I've Wd40'd it about 5 times and it's just not budging. Would 3in1 oil be a better alternative?

I've tried to shock it with a hammer and screwdriver but with no success and have just had the idea to maybe drill it out...but stopped and thought I'd ask on here before I go any further. 

You can see on the pic where I've started drilling and also the state of the area in general. It's a right mess isn't it?

[matsuba]

Now that's a good idea...a dremel! Why didn't I think of that? Thank you gazpx.

[sbwnik]

HSS Cobalt drill bits cut through most anything

[henri]

as gaz said dremel a slot an then impact driver an big hammer ,i always start a screw out with a impact if theres any doubt of it moving ,specially if somebodys re-used a mangled screw ,the little divels, an if that dont get it as swbnic said a decent hss drill will go through ,a careful centre punch in dead centre an then start small 2mm an be careful to keep it on center ,then work up an sometimes you can drill it out til you can pick the thread part out without damaging the pivot thread. if pivot thread gets trashed a oversize tap for a new thread an a high tensile bolt instead of a pivot bolt,
aswell as wd40 a bit of heat will expand the ali an could help to release its hold on steel bolt ,if you dont want to take the grip off or bar out an use flame wrap a rag round an put boiling water on it ,this will expand ali an give a gap for wd40 to seek into, Henri

[pxguru]

Maintaining the keep it simple theme, the nut has been removed from the back already, hasn't it? Just to be sure

[henri]

didnt think of that 1 ,mostly coz quite often there missing as not replaced previously or just fallen off with vibration.
henri

[matsuba]

Yes, I like your thinking pxguru! Simple always works for me! Unfortunately henri was correct in that the nut is none existent and looks like it has been for some time. I'm going out to get some cutting discs tomorrow and give that a go. Is an impact driver a screwdriver that is basically one piece of metal...like the one Sausage uses on his DVD? Will a normal screwdriver not do the job?

I'm not sure I could realistically drill through it as its so mangled that it's impossible to put a punch hole in the centre. As a last resort, if the dremel doesn't work then I've looked for new replacements and they are around £25-35 on the Beedspeed and SIP websites so it's not the end of the world if I can't remove the bloody sodding thing! Honestly, of all the parts I've removed so far I can't believe a single, simple, easy to reach screw is the one thing I've really struggled with!!

So, all I've done is remove both gear tubes/grips and now I need to order a steering nut ring spanner to get any further with this bloody front end. And I thought taking the engine out was going to be the hardest part...how wrong I was! I'm seriously at the point now where I just want to ride it and get out there...it's so frustrating how long it's taking me when I hardly get any time but I just keep telling myself it'll all be worth it and I'll so much more clued up and able to at least talk "shop" with other scooter people. I've just met a bloke who lives down the road who has one and he went out with a club last week on a ride and pics were on FB etc and oh man, did I wish I was there too!! Next year defo!!

Sorry for the rant and thank you for all your replies :-)

[sime66]

Get it off your chest; I know that feeling mate. If its any consolation I’ve just come out of feeling exactly like that and am starting to enjoy the riding again after almost all work and no play (scootwise) for the whole of this year. It is great feeling to know you’ve rebuilt it yourself though, and know what’s going on inside, and to have learnt something new every step of the way, so that next time you can tackle it with confidence.

Some of the chaps here come to enjoy this side of it more than the riding; I don’t think I’ll ever be like that, but it’s a good feeling of achievement anyway. For me especially is the independence that being able to do it yourself gives you; not having to rely on others, to investigate and select your own parts, and to have no labour charges and know that the bloke doing it (you) did the best job you were able – even if you made mistakes that you wouldn’t repeat next time.

Stick with it; it will be worth it.

Have a rant and a weekend off sometimes too – essential therapy!

- And isn’t it always a silly little bit you didn’t even think about that gives the most agro.

[vespasco]

Its difficult to explain but ill give it a go. ... ..

First, From the underside of that screw, make sure there are no burrs on the bottom of that bolt that would prevent it from turning. If so use your dremel to make the bolt flush and clean enough to use a centre punch/drill.
Then (on the underside/bottom of the bolt) try either centre punch and small pilot hole. Then with a cordless drill try screwing in a 'normal' wood screw , or a self taper, about 3 or 4mm diameter, into the bottom of that bolt, hopefully it will bite and at the same time turn and free itself!?
If you can drill a hole on the bottom of the bolt you could also try drilling it out as a last resort. You should be able to do that without having to re tap the handlebars.

Be careful with an impact driver as you could easily break off a piece of the handlebars. Then you would really swear.

[henri]

thats why i always refer to the manual as "haynes book of lies" ,where it says "you remove the 4 screws an the gizmo lifts off" .in some parallel universe maybe .
a impact screwdriver is a tool that twists the bit in it when hit with a hammer ,like a fat screwdriver with different bits ,straight,phillips ,allen an square socket driver.the force off hammer blow stops the bit jumping out of screw head an also loosens the screw ,
an whilst on "tool talk" ,cue giggles, most people knock of the fork stem nut with a drift of some kind,i use a brass bar ,most use a old screwdriver.it can destroy the nut tho, some bycycle c spanners fit but are awkward to use .if your going to buy the proper tool avoid the cheapy ones on e bay that look like a big socket with 4 pins at bottom ,the pins break off to easy , twisted rods do a decent 1 for about 19 quid ,
tho on the cosa i had to buy both ,the twisted one to fit the nut with its lever cut off an the indian 1 with pegs ground of welded on too it to reach down into the headset an torque up the nuts .
as with all scoots its the simple stuff that can trip ya up an stop a job progressing ,makes it more satisfying when ya sort it ,well for me anyway. as your 1 of those who actually insist on riding there scoots ,rather than a shed-dweller like me, riding a scoot knowing you built it an can fix it if it breaks just increases the pleasure an confidence .plus ups the bragging rights when ya thrash somebody elses. Henri