Suzuki GSX650F Forum - www.GSX650F.biz

So, I was finishing my late 7500 mi service and decided to service the front brakes and replace the fluid, and that's where trouble started. Though I've had the cap off several times on this bike, a tight fitting driver managed to round out both screws. Anyone done this? Which extraction method/tool/bit did you use? Anyone know the size and the part # for the screws?

The reservoir cap screws are 4mm, so take a #22 drill (.157) and using a electric hand drill, carefully drill down on the center of the head of the screw until the head of the screw pops loose.

Do this to both screws and remove the cap. The use a small pair of vice grips to clamp on the screws and and unscrew them. On flat head screws you can also sometimes break them loose by taking a small prick punch and carefully place it towards the outside edge of the screw angled at about 45 degrees, and using a hammer carefully drive the tip of the prick into the head of the screw, tapping it in the direction to loosen it.

Thanks! I was considering getting comething like this Grabit screw extractor bit kit. But I'm still unsure if it covers the small size of these screws. Is a 4mm screw about #8 in size?

I would drill it with a small drill, then you should be able to remove the cap and then remove the remaining bits.
But first get the 2 screws from a dealer and then leave it for two years or so.

I didn't know about the two years trick- will do.

BTW, the Grabit kit worked a charm- easy, easy, easy. Should anyone try the kit, be sure to use REVERSE drill direction for both the grinding and the extraction.