Howdy all, I was sorting a high beam/low beam issue on my 71 Bonnie and have come across this problem, the last person into the handlebars electrics had effectively rounded out the philips head screw that holds the plastic assembly with the horn and lights circuit. It looked like they had spun the screw over and over with an electric drill with a philips head bit in it, it was completely rounded out and would not take a screwdriver.
At the time my dremmel was in arms reach so I took the wrecked head off the screw with the dremmel and pulled the electrics out.
I then thought it would just be a matter of putting some long nosed pliers onto the rest of the screw and removing it and replacing it.
Unfortunately the frikkin thing is jammed tight, and I am terrified of snapping it off.
I initially went and bought a can of freezing lubricant, the type where you spray the stuck bolt and the snap freeze cracks the corrosion holding the bolt. No luck with that, so I tried the opposite direction, and got out my soldering iron and heated the bolt and tried again, no luck. Out of frustration, I did the soldering iron again, then hit it with the freeze treatment, still no luck. All this in the mean time slowly wearing what little of the bolt I had to get some sort of purchase on away.
It is currently sitting soaking with some penetrating oil spray on it, now before I go and buy a remarkably small pair of vice grips and try again tomorrow, does anyone have a sure fire remedy for this sort of situation?