Topic: 35 year old bolt removal?

[550Z]

Im trying to get these 10 philip screws off my 550 so i can service my clutch and shift spring but they havent moved for 35 years so whats the best way too remove them without stripping them?

[CrankyOldGuy]

I always have found an impact driver works.  I have successfully removed bolts from my 750 which have not been off for 35 years or so.

Harry O.

[Dimitri13]

Liberal use of penetrating oil (liquid wrench, PB blaster, etc). WD40 IMO isn't acceptable as it's more of a lubricant. Then some heat, followed by a quality impact wrench.

I had some issues with my clutch cover and had to dremel a slot in one, but I was just using elbow grease.

[550Z]

Ok cool i was worried because these screws are almost made of a soft metal and the previous owner tried too get them off and they are a little stripped....

[brewsky]

I use valve grinding compound to increase the friction of the driver tip.

Make sure you hsve a good quality driver or tip that fits snug.

Whack the driver in the screw first with a hammer.

I like the T handles best.

[lucky]

It is easy if you use the proper tool.


USE THE IMPACT DRIVER FROM THE VERY FIRST ATTEMPT .
NOT THE LAST ATTEMPT after the screw head is ruined.

FIRST take a small ball peen hammer and give each screw a couple taps.
This breaks the molecular bond going on.

Then using a #2 or #3 phillips bit in the impact driver (size is critical), Put the impact driver with PROPER fitting bit into the screw. Push on the impact driver while twisting slightly in the loosening direction on the screw and hit the driver with a good sized ball peen hammer.

Comes right loose.

FAILURE TO USE THE RIGHT SIZE BIT is 99% of the reason screws get stripped.
People too lazy to get the correct size bit.

There is NO SECRET !!

If you own a Japanese motorcycle you MUST own the impact driver.
HAND operated impact driver.

[550Z]

Do you think harbor freight tools has impact drivers?

[Bob Wessner]

You might want to have a look at this post and the accompanying thread.

http://forums.sohc4.net/index.php?topic=20131.msg209311#msg209311

[Dimitri13]

Don't use a HF impact driver/wrench. Every post I've read on here about them has been absolutely terrible.

IIRC the clutch cover screws are JIS (Japanese Industrial Standards)? You can tell if there's a dot on the head.


A regular phillips head is NOT the proper tool to use. I've used a #3 and it fits snugly, but some have reported that a drywall phillips works (source needed).

As a summary:
Penetrating fluid
Impact hammer/wrench !!FIRST!!, not as a last restort
Ensure the tool fits properly.

[550Z]

But would the acetone eat the protective coating on the engine? And all 10 screws have the dots on them... and they almost look like tiny crosses instead of dots..

[DJ_AX]

Impact driver is an amazing tool.
I got an HF one for about 8 bucks... busted and twisted the tips after a while. Bought some good tips
It didn't do damage to any of the screws. Although a few we're pretty bad already from the PO. It works great even on those.

[550Z]

Thats what i want to do i want to get a HF impact driver and get better tips like from Lowes or Home Depot..

[Don R]

I find the screwdriver that fits best and use the next bigger one. I have a snap on bit on a sears 19.2Volt impact driver that pops em right out.

[550Z]

Do you what replacement bolts i can get that are american made so that i dont have too go through this process again later in life?

[Accolay]

IIRC the clutch cover screws are JIS (Japanese Industrial Standards)? You can tell if there's a dot on the head.


A regular phillips head is NOT the proper tool to use. I've used a #3 and it fits snugly, but some have reported that a drywall phillips works (source needed).

As a follow up to this post, JIS impact bits are made, but I think the only set available anywhere is about $40 from Hozan:
http://www.ikaswebshop.com/hodsetofrebi.html

Or you could get the driver with bits for $117:
http://www.ikaswebshop.com/hodimsc.html

Fairly expensive IMHO, but if you're a tool guy you might like a set.

[lucky]

Do you think harbor freight tools has impact drivers?

Yes they have them and make sure it comes with all the bits.

[Dimitri13]

Do you what replacement bolts i can get that are american made so that i dont have too go through this process again later in life?

The thread diameter and pitch should be the same as any metric one. It's just the head that's different. IIRC they're M6 with a standard (1.00) thread pitch. Just take one to a hardware store and get ten plus a few spares (best way to check is get a nut that screws all the way on the bolt you have then match it to a bolt from the drawer). Just make sure the heads are about the same size, as bigger heads may not fit.

[550Z]

Ok guys so i got the impact driver and i got all the bolts off the clutch case and motor oil starts pouring out of it WTF is going on and i cant get the case off do i have to remove the kickstart thing? And why is motor oil were the clutch is?

[bollingball]

750 has a wet clutch not sure about the 550 but I think it does also. Have you downloaded the factory manual. It is on this site free. Also some people change over to Allen head bolts. People sell kits with all the ones you need for the bike All different colors plus stainless.

Ken

[dave500]

they both have a #$%*ing wet clutch,,you should have drained the oil first,,yes the kick start thing has to come off,#$%*.

[DJ_AX]

... and motor oil starts pouring out of it WTF ...

ha ha ... part of learning
We've all had our share of mishaps.
now get proper info .. and follow the steps  and understand..
... next time maybe try shortcuts

[550Z]

Ok i didnt know they had a wet clutch i was scared and thought i had a cracked block. I got the kickstart off and pulled the cover off... My clutch looks brand new and so does everything else inside. Now i need to get the spring for the shift lever back in place.. it looks like its not even touching anything.. which is probably the reason my shift lever gets stuck in the up position.

[dave500]

youll have to pull the clutch off,heres what it looks like behind it,this is a 500 but for all intents and purposes this photo will do.

youll need a pair of external circlip pliers to remove the clutch basket.
once you undo the four bolts and pull the lifter plate out itll look like this,,theres the circlip you need to remove,this is a 550 assembly,note the difference in the little spring and the angle at the top off the shift action lever.

[550Z]

Thanks ill take a look at it tomorrow morning since its to late over here.. And do u guys know whats the best online store to shop for CB550s?

[dave500]

when you assemble the lifter plate you can use one of the case screws to manhandle the pressure plate back towards the lifter so you can start the bolts easier.