Stripped bar end screw - Honda CBR250R Forum : Honda CBR 250 Forums
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Old 10-30-2012, 12:19 PM   #1
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Default Stripped bar end screw

So I installed my oxford heaterz Saturday and ended up stripping out the head of the brake side bar end screw when I decided to give the corded drill a go on it. I went to the hardware store and got a screw extractor and it actually removed the chuck from my drill (its ok, I hate that thing). I was able to get the screw out using the screw extractor and some locking pliers and a rag around the bar end locked down with more pliers.

The clutch side was not nearly as bad but did give some trouble.

At the hardware store they didnt have a matching screw so I ended up with a bolt which looks really bad. Anyone know where I can get some new screws? Or should I just take this opportunity to get some new bar ends?

The new grips are great btw. I just need new gloves now since the backs are mesh.
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Old 10-30-2012, 12:26 PM   #2
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Can't help you with your actual issue. I thought the topic was something COMPLETELY different
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Old 10-30-2012, 01:10 PM   #3
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You've got to be carefull with those because most people don't have a #1 Phillips bit and are tempted to use the standard #2 and end up stripping it out. I would go to the Honda dealer. They should only be a couple bucks.
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Old 10-30-2012, 02:54 PM   #4
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Definitely order yourself a new screw from a Honda dealer, either online or local. $3 Part #90191-KYJ-900

And while a lot of folks have $200 impact wrenches these days, I am not one of them.
This is what I use to remove stubborn screws:


$13 from this guy: Yamaha XS650 Impact Screwdriver with bit set - Mikes XS - New OEM & Vintage Parts Supply Warehouse
It's a really nice kit and has just the right size bit to fit these screws.

I just put on a set of Oxfords myself, today.
I had to have my nephew come over yesterday to help with the bar-ends.
I heated up the screw head because I really thought I was going to find Lock-tite in there. I didn't. But the 2nd one didn't budge until we heated it, too.
Anyway, I put on a pair of gloves and held the bar-end in place while Mitch smacked the hell out of the impact screwdriver with a 5 pound sledge.

As mentioned - the key to not stripping Phillips head screws is having the correct size bit.
Before things get too bad, you can always get an impact screwdriver (w/correct bit) and put some valve grinding paste on the tip on the bit. That helps to grip the head a little better.
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Old 10-30-2012, 03:31 PM   #5
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Thanks for the replies guys. Ill just leave the bolt in while I wait on a few new sets of screws to come in. I will also have to invest in that impact set at some point. I imagine it will come in handy.
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Old 10-30-2012, 03:39 PM   #6
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I am putting together an order of small parts for my first "factory" order.
I want to get a complete assortment of those plastic body fasteners. I think there are about 3 different styles used. I also need to get a replacement screw for the lower rear spot on my left under-engine fairing. It vibrated out before my first service. I had something on hand that fit. I also want to get a couple of the rubber washers that Honda uses to isolate the horn bracket. I think they would be good to use to take up the slack on the bottom front fastener of the left & right main fairing panels.

Stuff like that!
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Old 11-22-2012, 11:10 AM   #7
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Attempted to install my heated grips. I have successfully remove the brake side's bar end weight with harbor fright's $5 strap wrench.

While attempting to remove the the clutch side, I have stripped the bolt
Untitled.jpg

I do have a bolt extractor. Think it is too big as it just spins and won't latch on when I tried to remove the bolt. Does anyone have recommendation on what bolt extractor I can use to extract this screw? Size, part number, where to buy?

Last edited by eluo; 11-22-2012 at 11:11 AM. Reason: correct spelling
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Old 11-22-2012, 11:50 AM   #8
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Just watch Youtube videos and realized that I need to drill a hole first before using the bolt extractor. I'll give this a try tomorrow. Time to enjoy Thanksgiving with my family.
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Old 11-23-2012, 06:48 AM   #9
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I have an electric impact driver that I had to use on mine. It got them out fine, but on a mates I have to actually tighten one side up first. I went nuts on it trying to loosen it (it was the clutch side I think) and it didn't want to budge so I tightened it up a bit first and then loosened it and it came off fine. I can't get over how tight they are especially for having no thread locking compound on them...
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Old 11-23-2012, 09:57 AM   #10
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Quote:
Originally Posted by bods View Post
I have an electric impact driver that I had to use on mine. It got them out fine, but on a mates I have to actually tighten one side up first. I went nuts on it trying to loosen it (it was the clutch side I think) and it didn't want to budge so I tightened it up a bit first and then loosened it and it came off fine. I can't get over how tight they are especially for having no thread locking compound on them...
Thanks for the suggestion. I'll give it a try to tighten then loosing before resorting to the bolt extractor.

For anyone in the US looking low cost replacement bar end screws,
PowersportsPlus.com - OEM Powersports Parts from Honda, Kawasaki and Yamaha at discounts up to 80% off MSRP sells it for $0.55 and shipping is $1.75 for any order under $10.
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