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04 KX 125 Stripped & Seized Stator Screws
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First off, you need to use JIS drivers on Japanese bikes, then that wont happen. See the little dot on top of the screwhead? Thats JIS. Google it. You can buy them in sets or they even come in the factory motorcycle toolbags.
You can try an impact driver with a JIS bit, an external bolt extractor, or I really like battery pliers.
Yes, I’m decades late on the JIS front. I’ll give the impact driver a shot next. Re bolt extractor - you think that will work on a screw?
The female type extractor for nuts, they grab outside. You need the jis anyway, Id try a jis bit in the impact driver first. They dont look too bad. But if you keep using phillips in there you're going to be drilling them out.
Heat is probably gonna be your only hope.
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Reverse drill bits, if they don’t come out with that just use ez-out or some other type of bolt extractor (as stated below, last resort). Should have clarified.
The 2 that aren't too boogered up will likely come out with heat, a good JIS bit and an impact driver.
The one on the upper left, heat, and a nice sharp torx bit that will jam in the rounded out hole and get a good bite, and an impact driver. If that doesn't get it, cut a slot and use a big straight screwdriver bit on the impact driver. Be careful with the impact driver. Don't hit it hard with a huge hammer or you could crack the cases. This will also probably be easier if you take the engine out of the frame so you can lay it on it's side and hit straight down with more control.
If you get 2 of them off and not that really bad one, just grind the head off the bad one so you can remove the stator. Once the stator is off you may have enough of the bolt there to get a hold of and unscrew it.
Drilling and extractor are last resorts if none of this works. You will have to be very careful with those not mess up the threaded hole in the cases.
Update: 2/3 out. A lot of heat + drill/extraction
Replace them with flanged hex bolts, or socket head cap screws!
For heat (especially where you don’t want to put a flame), pick up an induction bolt heater.
If he just used the correct tool, not phillips, they come out just fine. Ive seen this 1000 times with vintage case screws.
Again, I was unaware of JIS screw head type.
All three are now out and I have a new set of JIS screwdrivers.
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