Brake reservoir screw head issue

[Stichill_imp]

(dang) I remember doing this crap back in the early 80's and thought: Can't they engineer these reservoirs better?

Take the best of a chemical and mechanical engineer and make the issue go away? Maybe it has ... in outer space, but not in the civilian domain.

Heck, maybe not use "Phillips" screwheads might solve half the problem.

I have replaced all similar screws on my m/c with TORX screws (popularly called star bit screws). Problem gone forever. So may be you'll save the dollars for the engineers, and just do it

I have a "damaged screw remover set", cheap enough to buy and effective. Only used it once or twice but it did the job. You just need a reversing drill, preferably with speed control.

Is this set "noname" or some special brand ?

Well, I tried multiple options...
Removed the other screw and tried wiggling the cover - No movement.
Tried the rubber band - Gouged out more.
Tried hammering in a slotted screwdriver and twisting - It looked like the small screwdriver would break.

I took it to a local bike shop here (incidentally the same guys who last bled the brakes in 2018). The mechanic wasn't confident he could drill it without damaging the threads. The suggestion was to get a replacement reservoir just in case this one gets damaged.

Does anyone know if either 45510-MGH-641 or 45510-MGH-305 would work? Revzilla says that 305 won't fit a 2014. I'm hoping I can find a used assembly.

I have a hard time understanding how one could start with a perfectly fine looking screw (nobody would put another one in), and a perfectly fine screw-driver, and end up with what you are showing in the photo. Wrong material, or wrong procedure ? Any thoughts ?

[ul] [li]Dissimilar metals[/li] [li]Galvanic corrosion[/li] [li]Maximum automatic assembly torque[/li] [li]No OEM anti-seize compound[/li] [li]Soft metal screws[/li] [li]Even proper JIS cross-head screwdrivers in good condition may fail to prevent cam-out for a seized screw[/li] [li]An area where Honda design succeeded in terms of cost control and mass production efficiency but failed in terms of maintainability
[/li][/ul]