Suzuki's practical joke?

WHoO-HoO! I got it!
Okay, here's the story.
I stopped by Wal-Mart this morning to get the extractors. Don't laugh, I work nights and thats the only place open when i get off
tounge.gif
. They had the extractors so I went ahead and copped 'em.
When I got home I went on and tried to get this done. I drilled a bit and tapped in one of the extractors, only to realize it didn't come with the handle. What to do, what to do? I'll drill a bit deeper, tap it in, and use a vice grip to turn it. So there I was with the drill just a drillin' away, when the darn drill bit snapped. When it snapped, the drill went up and forward, hitting my bike due to the pressure I was applying. "Awww FUQ!!!", I shouted thinking I scratched my tail again. Luckily it hit the frame, not the plastic. Screw this (no pun intended), I need to do this the right way.
I went to a local parts store looking for the handle. It just so happens I walked by some screwdrivers while I was there, some very BIG screwdrivers. Hmmm I thought. The other one twisted, maybe this one would do the job. Just to be on the safe side, I bought both. Bad thing is , they don't sell the handle alone so now I have 2 extracting kits.
Now, the head on this screwdriver is about 1/2 inch wide, nearly twice the width of the other one. Figuring it made no sense to have 2 extracting kits, I decided to work with the screwdriver 1st. If it works, I can take back the second extracting kit. The first time I tried the bigger screwdriver, I realized the slit I originally cut was too small. I broke out the dremel tool and went to work making it suitable for the new driver. I placed the driver back in but my hand kept sliding around the handle. BRAINSTORM!!! I drilled a hole through the handle of the big screwdriver big enough for the 1/4" driver to fit through. Basically now, it looks like "+". I placed the driver back into the slit and used the other as leverage.

POP!

I thought to myself, "This is rediculous. Even with a bigger screwdriver, it still slips out". I looked at the screw one more time as if to tell it "Okay ... you won", but what I saw lit up my eyes. The slit I had cut horizontally was now nearly vertical. YESS!!! It finally moved! I immediatly placed the screwdriver back in, and I couldn't keep the corners of my lips from touching my ears as I now easily turn this demonized screw.

This weekend I'll do the screens and post some before and after pics as well as a pic of this screw from hell.

Thanks to all for lookin' out.
 
Just did this on my friends 05 blue and silver last week. What a pain in the ass. Same bolt too. I just made the slit across with the dremel as big as the biggest straigt slot I could find. Then my buddy leaned against the throttle side of the bike while I turned and pushed at the same time on the bolt. Finally got it out. The key to the whole thing is pressure and leverage. Good luck.
Once you have the slot, you can use an impact wrench and hammer to add the pressure and counter rotation. You can pick up an impact wrench at any hardware. They look like a heavy metal handle with a male socket end. You can put an included attachment on like a socket that holds a flat screw driver bit. Then, put the blade in the slot, twist all the way left holding firm and wack the crap out of the back of the handle with a hammer. You can twist and wack until the screw starts to move freely.
 
grind a slot toward the outter edge and us a hammer and chisel to force it around.



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