Help needed removing brake lever hex bolts

Unicornz0 · Apr 12, 2010

Hello, I picked up this Specialized Enduro, and the hex bolts that hold the Hayes brake levers to the handle bars are deteriorated. The hey key will not grip the inside of the bolt firmly. I'm looking for ideas about how to remove the hex bolts without damaging the break levers.
Thanks in advance,
Uni

the-one1 · Apr 12, 2010

Drill off the head and the once the halves are apart, you can remove the stub.

oldskoolbiker · Apr 12, 2010

Maybe use a dremmel cut off wheel and cut through the bolts in the opening between the lever and clamp.

Bikinfoolferlife · Apr 13, 2010

Wedge a slightly larger allen in there and see if you can get it undone that way would be my first try before getting crazy with easy outs/drill/dremel etc. If I did start cutting I might try making a screwdriver slot out of the bolt head first, too.

Unicornz0 · Apr 13, 2010

Thanks for the help Everyone. Please keep the ideas coming. They seem to get better and better.

jay80424 · Apr 13, 2010

2nd the drilling of the button off.

You could also dremel a slit across the head, and try to unscrew it with a large flathead.

Soak it in triflo or some other penetrating oil first.

temjin006 · Apr 13, 2010

I prefer to use a dremel to cut a slot across the head. This method is easier and fast. I got alot of hex head screws with stripped head and threadlock on the threads from my RC days with this method.

mojotrick · Apr 13, 2010

The screws will have to be replaced anyway. You can either try to cut a slit in the head of it with a dremel to use a flat tip screwdriver or just use a drill bit a little smaller than the head and drill the head off.

wv_bob · Apr 13, 2010

Try a torx bit or driver that'll fit snug in the hex head

damnitman · Apr 13, 2010

http://www.aldn.com/grabit/

b-kul · Apr 13, 2010

id go with slotting the head and if all else fails just hack it off.

bvibert · Apr 13, 2010

I'd try, in this order:

-Force larger allen in there (maybe slightly larger inch size instead of metric)
-Pound in torx bit (may damage bit)
-Slot the head and use large screw driver (if I had a dremel and a cut-off disc available)
-Easy out (something like the Grabit mentioned above)
-Drill the head off and remove the shaft with a pair of vice-grips once you get it apart

AlexRandall · Apr 13, 2010

you also could get a flathead screwdriver which has a head the same size as the widest part of the hex. This often works without getting the cutting tools out.

jogden · Apr 27, 2010

temjin006 said:
I prefer to use a dremel to cut a slot across the head. This method is easier and fast. I got alot of hex head screws with stripped head and threadlock on the threads from my RC days with this method.

+1

Help needed removing brake lever hex bolts

Unicornz0

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the-one1

oldskoolbiker

Bikinfoolferlife

Unicornz0

jay80424

temjin006

mojotrick

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damnitman

b-kul

bvibert

AlexRandall

jogden

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