The Philips head is on the verge of being unusable.

I can twist the bar end itself but the screw is stuck.
The force it takes to twist the screw is higher than the force needed to destroy the screw.
I haven't tried using an impact drill with a philips bit yet but this will probably just do more damage.
I might try to put a dab of glue on the head and twist the bar end.

Any other ideas?

btw if you still have the philips screws in there I suggest replacing them with an Allen before they rust or become stuck due to some other reason.

Grind a slot, and use an impact wrench, the kind you hit with a hammer 

EDIT: Or maybe drill the head off the Phillips?

Even with JB Weld i doubt the glue idea would work.
Go with the impact driver for now and if u can get a second person to firmly steady the handlebars while u hit them that would help.
Looks like it's a JIS head,not Philips.

Quote from: fetor56 on April 01, 2016, 02:55:52 PM
Looks like it's a JIS head,not Philips.

At this point it's actually toast 

Quote from: Suzuki Stevo on April 01, 2016, 03:17:30 PM

Quote from: fetor56 on April 01, 2016, 02:55:52 PM
Looks like it's a JIS head,not Philips.

At this point it's actually toast 

Toast or not it started it's life as a JIS,and no doubt if the right tool was used the screw would be undone.
Possibly Yianna doesn't know about this standard.

How about drilling it and using an "easy-out"?

If you don't care about the bar end or can replace it you could try a hacksaw down through the bar end and cut the head off the screw.

With the head gone there will be no force holding it in place and you can unscrew it with your fingers or pliers.

Also get some JIS bits or drivers so this doesn't continue to happen to you.

http://www.vesseltools.com/hand-tools/screwdrivers/impact/980-series/flypage.tpl.html

Here is what you shoulda used!   yeah too late now...but spend the $$$ and buy yourself one for the next time.  One use and it pays for itself.  (saves big $$$  ruined parts).

Spend the cash now and you only cry once.


Cookie

Hallo. Had the same problem with my 94 gs500.
What i did was, i drilled the head away, then i could take the barend off and the screw would still stick out, just enought to get a akku driller to attach on it, and just take it out.

Hope you understand.

Smash the bar end hard, from 90 degree angle, with a heavy rubber mallet, and it will pull right out. The only thing touching the inside of the bars is a rubber spacer and the rims of two flange nuts. The force will bend the head of the bolt down and pull everything else out an inch or so, without damaging the bars or lead bar end piece. This is what it's designed to do. Then run down to home depot and get $2 replacement bolt and nuts.

Do your self a favor and go down to the hardware store and get an impact driver (the hand held ones you use with a hammer...not powered) and some JIS (japanese industrial standard) bits.  It will likely be the best $30 you spend on tools for this old bike. You should still be able to grab that with the impact driver. Stay away from the easy out tools....perhaps a left handed drill bit might grab it but you could also just drill off the head of the screw, remove the end weight and then use some vice grips to turn the left over bolt shaft out of the thread in the handlebars. good luck

I got it out, finally.


I pounded on the JIS screw with a large flathead and a hammer until I got a deep enough slit in there for the screwdriver. Then I simply unscrewed it.

Nice job! Glad you got it out.