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Stornello Screw Up

Bill Hagan

GT Reference
GT di Razza Pura
Joined
Oct 29, 2008
Messages
1,700
Location
Above Pott's Camp along Braddock's route, Virginia
So, the challenges of removing "frozen" fasteners have been treated here a bit, but this one is a bit more problematic (for the likes of me, anyway) as it involves some potential cosmetic damage.

So ... I was trying to remove the "number plates" from the Stornello. Those are attached to the outside of the larger side covers. Long story as to why I am doing that, and they may go back on, but now I need them off.

No problem on right side; easy-peasy. Ah, but see first pic.

Left side is a female dog.

The forward M4x25 button-cap screw -- #8 in the parts pix -- that holds the number plate on will not budge. I have now also managed to round out the (POS) soft 3mm hex hole.

Tried heat. No joy.

I cannot grab hold of the head of the button-cap screw with any tool I can find.

Is the standard "dremel a slot for a screwdriver" the best approach?

Other suggestions?

Bill
 

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Is the standard "dremel a slot for a screwdriver" the best approach?
Yes, then a drill bit to remove the head if that fails. I too hate the garbage fasteners they're using these days too.
 
Try jamming a torx head bit in where the hex used to be. Pick a size that needs a hammer to insert.

I've had a lot of success with this simple method.
 
Bill,

If Kiwi's suggestion doesn't work, see if you can locate left hand drill bits. Sometimes when they bite in they will remove the fastener. If all else fails, it may need a machine shop using a carbide tip.
 
I had to use a Dremel and carefully cut a slot on a side cover fastener on my bike. It worked and I replaced all my side cover fasteners with stainless ones with much better hex holes.
 
After my coffee -- a touch of grappa seems apt this morning :drunk: -- I'm going down to the Moto Grappa to try out some (and possibly all :giggle:) of those options.

I actually have the dremel, torx set, and (HF!:giggle:) impact driver in my set of tools (to be avoided :whew:) in the Moto Grappa.

We shall see.

Thanks to all for the options.

Bill

Edited to add that I ordered some new replacement fasteners -- https://www.amazon.com/gp/product/B012TI59J2/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 -- though not sure quality any better than the OEM. If so will, get some other sizes, too. As I'll have a lifetime supply (and more!;)), happy to share. Let me know if interested.
 
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There's always that one it seems, easy out (screw extractor kit) did it for me on my valve cover bolts.
 
Well, declared victory over that reluctant fastener today.

What a PITA. The “make it into a screw” was the winner. Note ATGATT. :party:

I was a little concerned about banging a torx into it given the somewhat “delicate” way things were. And, after extraction, the screw seemed to have some blue loctite on it ... which was trying hard to be red. ;) None of the others did.

Anyway, will leave the side plates off for awhile. Something about them smacks of “boy racer” and motocross or trials wannabee. That said, not sure I like the black side covers — even with my matching Carabinieri decals.

Thanks again for the support and ideas.

Bill
 

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