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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Foot Brake lever
Post Info TOPIC: Foot Brake lever
Flying Dodo


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Foot Brake lever
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Hi All,

I had a large departure from my TTR a while back which thankfully damaged the bike and my ego more than me! Most has been easily fixable but the stud on which the brake lever is mounted snapped at the thread! It looks as though maybe there has been a previous repair! Any bright ideas haw to get the threaded part of the stud out or fashion a repair - I'm trying to drill it out but it's very hard material and impossible to drill straight. I'd rather not strip out all the engine etc. to get it onto a pillar drill. Any ideas?

Cheers

Dave



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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
Flying Dodo


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Should have said - I live in France so don't have the luxury of a decent mechanic shop.


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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
mossproof


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Have you managed to drill into it at all? If so, you might be able to hammer a torx bit into the hole (be prepared to sacrifice the torx bit!) The stud should not be too tight as the face it tightens against has broken off. Plenty of soaking with wd40 first and you might be lucky (sometimes it works!)
Good luck!

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comeragh


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Had the same problem .Bolt is super hard to drill .I ended up drilling it and retapped it but it  threaded section broke from frame  after and it floating in the frame for about 2 years .The pivot wont actually fall out in use as half  it is inside the frame  so just kept using it with no problems  .In the end iplan to  just drilled it all out and welded new nut inside .Its a very awkward job .It made me realise the high  quality of  bolts that yamaha use .



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TTRfan


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I had the same issue whilst on a trail riding holiday in S Ireland so I didn't have access to a drill.

The broken off section was so hard I was able to break/shatter it out in pieces using a punch and hammer. Hard to believe but true!

The threads weren't damaged and I was able to use an ordinary bolt as a temporary fix until I got home biggrin



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Flying Dodo


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Thanks Guys, I'll attack it with renewed vigour and a bigger drill now I know some alternative solutions, I have got so far in with a smallish drill bit, after breaking several drill bits, and am now trying to get in with a 6.5mm bit in the hope of attacking it with a stud extractor (or Torx) - but I'm not hopeful on that one! I'll let you know, thanks
Dave.
Happily the spare bike is running well for the moment.

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Provence FRANCE, 2005 TTR250 (x2), Harley 883 for the roads. Oh yes and the wife's XT125X.
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