So all your old engine case screws are chewed and rusty...

The pan-head Phillips screws securing most older Japanese engine cases are a very soft metal - very poor quality - rusting and rounding all too soon.  Not only do they get progressively more difficult to remove as the head gets more and more chewed, but the rust detracts from the looks of the bike.

These replacement stainless steel Allen bolt sets from Dr Bolts offer high-quality replacement bolts for most of the Phillips pan-head screws in the visible engine cases.  Each set contains a matched set of polished stainless steel bolts with the appropriate sized Allen wrenches.  In some sets a handful of washers are also provided to shim bolts where the OEM manufacturer varied the length of some bolts (the Kawasaki KZ1000 is a good example, the sprocket cover bolts varied in length by a couple of mm when Kawasaki modified the engine cases to thicken them part way through the production run).   The descriptions for each set details the covers and number of bolts for that set.

Putting the new bolts in is easy in most cases, the toughest part is removing the existing Phillips head screws.  The best way to remove the old screws is with an impact screwdriver.  These tools are a valuable part of the toolkit for anyone working on old Japanese motorcycles.  Just make sure the bit size matches the Phillips head bolts size - if the head is a little chewed, tapping the impact screwdriver bit into the cross-head will often force the bit firmly into the old bolt and allow it to be removed easier.

Click below for bolt sets by make
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