Stripped/Stuck Hayes Brake Lever

[awol12]

Just got a new bike and was making all the necessary placement adjustments and whoever built the bike up tightened the brake clamp bolts down a little too tight. So know one of bolts has a stripped out head and I can't get the brake lever off. I emailed hayes and they suggested remove the second clamp bolt, slide the lever off the handle bar, and then get the bolt off using some pliers. Here's the next problem though, even with one bolt completely off I can get the brake lever to budge on the handle bar. I can twist it a up and down, but can't get it to slide sideways at all! Can't believe it is still that tight with only one bolt attached. At least I know that once tightened these brakes aren't going anywhere.

[vintagefisher]

try a reverse-threaded drill bit. One that is small enought that it will go in to the head of the bold without damaging the threads. If that itself isnt enough throw a bolt extractor in there.

[roffles]

Try using a flathead screwdriver as a wedge to slightly open the clamp where you removed the second bolt. Then try to twist while pulling it off the bar.

Sent from my PG86100 using Tapatalk 2

[300hp]

slather your bar in white lithium grease. Once you get it to move a little bit, you'll be golden,as bars taper towards teh end

[iamkickstand]

use a BFH, works every time, if that doesn't work, get a B'erFH

[awol12]

should I get the spray on grease or the tube? Not sure about the hammer, don't want to damage anything.

[iamkickstand]

should I get the spray on grease or the tube? Not sure about the hammer, don't want to damage anything.

any kind of grease will work fine. even motor oil may do the trick.

I was joking about the hammer.

[awol12]

I figured the hammer was a joke, but let me tell you the thought definitely has crossed my mind a couple times. Mostly for the genius that tightened them down that much!

[bansheesho]

Another trick I use a lot as an automotive technician if the head isn't stripped out too badly is to squirt course valve lapping compound on the tip of the Allen wrench... It fills in some of the space and gives it a good bite. It also works on Philips head screws and torx heads too... Much faster than drilling. You may also try applying some heat to the body... Not too much that it damages the component, but like a hair drier on high... It helps to loosen the loctite

[iamkickstand]

Just kinda thought about this.

A new brake clamp/lever, etc is expensive. A new handlebar is not and neither is a new unstripped bolt.

worse comes to worse cut the bars before doing irreversible damage to the brakes.

[bergsteiger]

Another trick I use a lot as an automotive technician if the head isn't stripped out too badly is to squirt course valve lapping compound on the tip of the Allen wrench... It fills in some of the space and gives it a good bite. It also works on Philips head screws and torx heads too... Much faster than drilling. You may also try applying some heat to the body... Not too much that it damages the component, but like a hair drier on high... It helps to loosen the loctite

this is a great tip

[awol12]

So I got it off. Greased up the bar and then slid the handle off. I got the idea of using a torx bit from another a site when I did a search and the torx bit was actually able to bite enough to unscrew the bolt. Now I just need to find a new bolt cause that one is stripped to *beep*. Thanks to everyone for all the ideas.

[classrc]

Assuming the bike was recently purchased, the shop that fubar'd it should replace the bolt, no?

[awol12]

For sure, but the shop is in Cananda. Got great deal on the bike through Pinkbike, but now I have to deal with no real support. Also haven't a shop in the area that has the bolt yet. Looks like I be doing a bit of driving around till I find one that fits.

[bansheesho]

You can probably find one that will work in the specialized bin at home depot... That will at least get you on the trail... Then you can order what you need