5 Techniques to Remove Damaged Screws from Your Motorcycle

When undertaking any task, it is natural to expect the process to flow seamlessly, and this is especially true for motorcycle mechanics. We assume that with a simple screwdriver, all screws can be effortlessly loosened and removed. However, the harsh reality is that some screws can be stubborn and refuse to budge, leaving us feeling defeated after hours of sweating over them.

As a novice mechanic, encountering damaged screws, such as those that are rusty or loose, is not uncommon but can be frustrating. Therefore, in this article, I will provide you with some tips on how to remove damaged screws and get your job done.

Removing Damaged Philips Screws: The Basic Technique

Philips screws are highly prone to damage, particularly in motorcycle engines. This is because they are tightly fastened during the manufacturing process. If not handled carefully, old and rusted screws can be easily damaged. It is crucial to exercise caution while using an impact driver, as any mistake can cause damage to the screw head or tip, making it impossible to remove the screw.

Damaged Philips Screws
See the differences between them

The screws on the motorcycle fairing are quite easy to loosen with a screwdriver but it becomes extremely difficult if the screws are rusty, even a bottle of WD40 can’t help it.

motorcycle fairing rusty screw

Have you ever seen a rusty screw on a motorcycle fairing like a picture above. For me that kind of screw is the hardest to remove, sometimes I have to sacrifice the fairing itself.. ūüôĀ

Before attempting to use this technique, ensure that you have already attempted to use appropriate spanners on that screw first. If the screw still does not budge, then continue reading.

It’s important to note that this technique is just a basic one, and you may need to adapt it to suit your specific situation. Firstly, let’s examine the common type of damage that occurs on Philips-type screw heads – damage to the screw thread.

1. Remove the screw using a Pliers

Above is a picture of screw head damage that causes it to fail to open out. If you get a screw like this on a flat part then it can be solved by using pliers. You can use Vise Pliers or Grip Pliers. Grasp the side of the screw head firmly and turn it. Later, after the screw is loosened, you can continue with the screwdriver..:)

Remove the screw using a Pliers

If the damaged screw is in a narrow space, of course, you can’t use this method, so you can try this second technique.

2. Fixing the damaged head

To fix a screw with a damaged Philips head, you need to reshape it so that it fits securely into the screwdriver tip and doesn’t slip out. An old tire axle shaft is a great tool to punch the damaged screw head, but you can use anything similar.

After punching the head to make it flat, you’ll notice the expanded screw tip has shrunk due to the impact. Next, force the screwdriver bit to fit snugly into the screw tip, with no gaps. This ensures the head won’t loosen when you punch the screw again. Once everything is set, you can use an impact driver to punch the screw and complete the repair. watch the video for a better understanding.

This technique is suitable to apply to the screws on solid iron floors such as a screw on motorcycle engine parts and chassis.


3. Using a Punch to Remove a Stripped Screw

If the first two techniques did not work, don’t worry, there is still a third technique you can try. However, please note that this method may result in the damaged screw being completely unusable.

punch the damaged screw

To use this technique, you need to punch the side of the screw while rotating it counterclockwise. It is important to use a punch that is not too sharp, as this can cut the head of the screw out.

4. Welding

The last technique for removing a damaged head screw is to use welding. To do this, you can weld a “T” handle to the top of the damaged screw, allowing for easy rotation and removal. It is important to note that this method can render the screw unusable, so it should only be used as a last resort.

5. Damaged screw&bolt extractor

Additionally, an extractor tool can also be used to remove a damaged screw or bolt. However, this method is more suitable for larger-sized screws or bolts.

Damaged screw&bolt extractor

In conclusion,

we have discussed various methods to remove damaged screws from your motorcycle, including the use of pliers, a rubber band, a puncher, welding a T-handle, and using an extractor tool.

Each of these techniques requires patience, skill, and attention to detail, but with persistence and the right tools, you can successfully remove even the most stubborn of screws. Don’t give up if the first method doesn’t work, try another until you find the one that works best for you. We wish you this post can help you in completing your motorcycle repairs.

Scroll to Top