How to remove stuck screws?

moppy · World Chat Champion Joined: 26 Apr 2011 Karma :

Decided I'd have a go at taking off some of the fairing on my ZZR6 today and having a look at the downpipes, do some general cleaning etc. It was going well for the exterior screws but as soon as I got to screws that were on the "inside" of the bike, so many of them were just seized stuck and no amount of WD40 would loosen them.

There are just generations of mud & dirt caked on to the screws & bolts, and I could not loosen it one bit. My screw driver is shit though, need to buy a new one, but is there anything else I can do to help loosen these? I would love to be able to take all the fairing off and clean it individually, make it look nice, then stick everything back on etc.

Are things like these something good to replace the old bolts with as well?

Babba · Banned Joined: 05 Jan 2012 Karma :

Despite what it says on the tin WD40 is NOT a good penetrating oil.

You need PLUSGAS to stand any chance of getting oil into those threads. Soak, soak it again, then let it soak some more. For totally seized fasteners I like to let it have at least 12hrs.

ALWAYS use good quality & well fitting tools. Halfrauds Pro range is the minimum level of quality you should be using if you want to be fiddling with bikes.

Stuck fasteners should be tackled in a strict 'order of priority' manner, there's no point attacking them with angle grinders or oxy acetylene untill the easy options have been tried first.

I'll start you off with No' 1. Strike the stubborn fastener, gently at first, with a hard hammer. Get some shockwaves passing thru it to see if that'll loosen whatever's gripping it.

Good luck.

The Artist · Super Spammer Joined: 06 Jan 2008 Karma :

HEAT, more HEAT

moppy · World Chat Champion Joined: 26 Apr 2011 Karma :

But this is screws into plastic. Wouldn't hitting it with a hammer risk the plastic cracking too? And as for using heat, again, plastic melting?

Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

If they're stuck, you'll have to do something to get them out.

PLUSGAS, then impact driver, then try cutting a slot and impact driver again, then drill the heads off, remove the fairing, and extract the studs with mole grips or similar.
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The Artist · Super Spammer Joined: 06 Jan 2008 Karma :

nofear · Derestricted Danger Joined: 31 Aug 2010 Karma :

Try an Easy Out set.

I had a bugger of a screw that refused to come out on my handlebars. I tried absolutely everything to get it out but it wouldn't budge.

Got one of these

https://www.axminster.co.uk/axminster-cobalt-drill-and-easy-out-set-prod462398/?src=froogle

and it came out on my first attempt. You will need to replace the screw afterwards though.