Removing tight (now stripped) screw from hard-to-reach place?

[vxd]

I'm trying to remove the air filter box but there is 1 screw that is now stripped.

Prior to stripping it I did spray wd-40 over a period of 2 days but the screw didn't budge.

Now today after more trying it is now stripped.

I've purchased a screw extractor but because of the position of the screw I cannot get the drill to reach it (edit: not screw driver) in.

What do you guys recommend?

The bike is a Suzuki GN250

[Reece]

Can you get a set of needle nose vice grips on it just to break it free.
I had the same problems with and old bike I was doing up a couple years ago replaced them with Socket head cap screws.
Hope you have a win with it.

[T.W.R]

6mm drill bit and drill the head off..... it'll come off like a washer, then vice grips on the screw shaft

[unstuck]

Yuuup, what he said. Looks too flimsy for an impact driver. Only do not drill too far, or you will have no shaft left to grab.

[Fastmark]

Only do not drill too far, or you will have no shaft left to grab.

That my friend is a life lesson right there.

Oh and agree with the method of removal, having done the same thing a number of times when re-building jap bikes with cheese head screws

[vxd]

The issue is I cannot fit the drill in there. The gap is too small.

[T.W.R]

Those screws are mostly M5 so a 6mm bit will break the head free before eating away to much of the shaft, also the depth of the cover gives a few mm of meat to play with.
Use a long shaft drill bit.....you can get them in a variety of lengths, 200mm is common and would be more than enough to do the job.
The heat created from drilling the screw head off is also usually enough to free up the thread too.

[Devil]

Depending on access, and how big the screw really is you could get a flathead screwdriver and a hammer (I have a sacrificial screwdriver for this purpose) and knock a notch in it, then undo with flathead.

[buggerit]

try a bit of oil based valve grinding paste on the end of your screwdriver
get a long series drill bit from the likes of trade tools(careful when you start)

[george formby]

I'm guessing the head is butchered coz you could not get a decent bite with the screwdriver. If you can't drill it what about cutting a new groove into the head with a hacksaw blade then using a driver on the end of a socket wrench to try & unscrew it? I've had to resort to such things in the past. You will need tea & biscuits while you fiddle.

[Big Dog]

Depending on access, and how big the screw really is you could get a flathead screwdriver and a hammer (I have a sacrificial screwdriver for this purpose) and knock a notch in it, then undo with flathead.

You can pre soften the head, and possibly free the thread by heating before notching with a soldering iron. Let it get hit but not red hot or the adjoining plastics will be at risk. I have to add though let it cool down before attempting to undo. Or you will have a screw with no head.

When I have done this in the past I have taken my time to heat with the iron and cool it with water a few times to harden the head a little.
If you have a spade but for your iron that does not overlap the screw this works even better.


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[BigAl]

Can you get a hacksaw blade in vertically?

If so cut the tab off, remove air box with screw & tab still attached, remove screw, cable tie the air box back in using screw hole.

[vxd]

Thanks all, The area is so small I'm going to give the soldering iron a go or I find a longer drill bit.

I did manage to get a drill bit (I think it was a 4mm) and it started chipping the screw, sparks were going off and pieces of the screw head was flying everywhere. So I'm a bit worried about trying that again.

[scumdog]

IF you can get candle-wax melted into the threaded hole (that the munted screw is living in) it can help it being undone - just make sure the threaded area is fairly warm when you try to unscrew it...

[HenryDorsetCase]

The issue is I cannot fit the drill in there. The gap is too small.

can you get a hacksaw blade in even with say 50mm push pull room? You can cut a slot in it and try to turn it. It will not work it will break the head in half but at that point you can muppet wrench it with more cuts. that will leave you a shank standing, pull the airbox off, and away you go.

also.... drill bit extenders are a thing.