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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Removing a broken stud
Post Info TOPIC: Removing a broken stud
TTRfan


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Removing a broken stud
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I have had a bad morning in that everything I want to work on is broken or damaged no

I needed to renovate a front brake master cylinder and I guessed from looking at the cap screws that I wasn't going to get them out without major surgery and so it proved!

So I drilled off the heads and removed the cap leaving a small amount of stud showing. It wasn't possible to get ahold of it with pliers or Mole grips so a Plan B was needed. I decided to try and drill them out using a LH drill bit but I managed to break the only one I had cry

Plan C involved getting the MIG welder out and trying to weld a nut onto the thread and winding it out. Didn't work - I was all over the place with the weld. So a Plan C was needed confuse

I rootled through my nut/bolt/washer box and found two substantial washers that just fitted over the studs, The photos below show the extraction of the RH one. I left a washer on the LH one to clarify what I did.

After a couple of attempts I had managed to weld the stud to the washer and then wind the stud out with a pair of pliers on the washer - phew! Just the other one to go then hmm

Removing stud 1.jpg

Removing stud 2.jpg

Removing stud 3.jpg



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mossproof


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Weldone Brian!-) It's a nasty job those tiny bolts. Sometimes some localised heat helps - have you got one of those gas powered soldering irons that the cap unscrews to reveal a little blowtorch flame? Ideal for easing spoke nipples too! Doesn't have to be glowing, just enough to allow the metals to expand and contract against each other releasing the corrosion.
What on earth happened to the clutch perch in your other thread btw? Has the project bike had a hard fall?
Mama said there'd be days like these!
Keep going, it's worth it in the end.
Simon.

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TTRfan


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Luckily it worked on the LH stud as well biggrin

I managed to get one out on another master cylinder seeing as I had the kit out and it was going well but the technique failed on one that I had unsuccessfully tried drilling out and had nothing protruding no

Yep - got a nice Pro-Torch which has its uses but didn't try it on these for some reason.

Pro-Torch.jpg

 

Regarding the clutch perch, I think I must have sold the last one not thinking to keep one back for the project bike disbelief

Brian

 



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ttr steve


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You can borrow one from your first ever TTRsmile It is only waiting a full restowink



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