Gear Selector Sheared Bolt

[alithehat]

Hi all,

It's my first time posting, but have been lurking and lapping up the info available here for quite a bit now! Hope all are well, and I apologise that my first post is a plea for help!

I have recently acquired a '09 plate CBF125 - now to call this thing a fixer upper would be an understatement. First baby on the way, every penny accounted for and so struggled to get the purchase past the girlfriend/boss at all - so it had to be cheap, and I figured the bike would teach me a bit along the way as I try to put it right.

The bike has clearly had its fair share of drops, and whilst most of the damage is cosmetic, the gear selector lever has taken a bashing and is sufficiently bent that it means getting into first/changing down is harder than it needs to be.

Not a problem, thinks I...I have sourced a new selector lever to fit to the linkage and away I go...however, the moment I put socket to bolt to remove the lever, the bolt head shears cleanly away leaving a completely flush bolt shaft stuck in place - I think the impact that bent the lever has also bent the bolt.

My question is...how the heck do I get that out? Is there anything in that bolt shaft (other than my sheared bolt), or is it simply there to secure the gear selector lever...could I just drill the bolt through and out? Exactly how much damage could my cack handed lack of experience do in this situation?

Any help would be gratefully received!!! Cheers chaps!

[Aff]

A picture would help.

Is it the pinch bolt?

:edit:

https://www.bike-parts-honda.com/thumbs/h/motog/17KWF901/IMGE/720_280/F__1900.jpg

Part 22 or 20?
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Taught2BCauti...]

A photo would help!

If it is bolt 22, you should be able to disconnect the linkage (3) and slide off the selector lever (1) and be able to remove the rest of the bolt with mole grips. You might have to hammer the selector lever back towards it's original alignment - but since you have a new one to replace it, don't worry too much about damaging the old one. You could probably get a small angle grinder or Dremmel tool in there if needs be.

If it is bolt 20, you should be able to disconnect the linkage (3) and force the actuator (2) apart with a flat-bladed screwdriver or cold chisel until it splits.
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Honda Varadero XL125(V8)
www.TheFutureIsHere.eu

[Vincent]

[KnuckleShot]

Exactly the same thing happened to my bike the other day when changing the gear lever.
The head of the bolt snapped, with the lack of tools I have to improvise and resulted in getting a screwdriver on the bolt smacking it with a hammer so we can turn it, only took about 30 mins to get it out.

[alithehat]

Thanks for the info chaps - it is bolt 22 - picture attached (i think)

Having had another look at the bike there doesn't appear to be anything else within the bolt shaft that I could damage...my current plan of attack is to go at it with a left hand groove drill bit with the drill on reverse...and hoping that should draw it out.

Possible? Or stupid??? Or anyone with any better/tried and tested ideas?

Cheers again fellas

[Aff]

Pull the linkage off and you should have some bolt sticking out.

Drown it in penetrating fluid and either attack it with some mole grips or grind a flat into it and get it out.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Pete.]

Trouble is that the bolt (or at least the washer) stops against the flat end of the pivot shaft so with the head sheared off there will be nothing to grip. There would be a number of way to attack this depending on what tools you have and why it's snapped.

If it's snapped because it's corroded in then the left hand drill bit is quite a good idea. Take a 2 or 3mm drill and pilot it then hit it with a 6mm left-hand drill. It should catch and wind the broken bit out. Take great care not to snap that drill though.
If you have a welder you could put a nut over it and weld down the hole to fuse the stud to the nut then wait 30 seconds and try winding it out.

If it's snapped but moving somewhat then an easi-out will remove it, or even putting two hack-saw blades on a hack-saw and cutting a wide groove right across the middle will allow you to wind it out with a large screwdriver. Won't affect the operation of the pivot or lever.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[alithehat]

This is it, exactly - the bolt has sheared in such a way that it is completely flush with the shaft...so nothing to grip on to at all.

Not sure on the reason for it snapping - it sheared really easily with next to no effort on the socket - I think that it may have been slightly bent from the same drop that damaged the selector lever, and so was weakened sufficiently that it took no effort to snap.

Because its so flush I am not sure if there is any movement at all - I like the idea of the hacksaw and screwdriver, as it seems a simple and elegant solution -i.e has the least variables for me to do something daft and make a hash of things. Failing that will bust out the drill.

Thanks for all the advice - will let you know how I get on.

Cheers

[Pete.]

Pilot the bolt with a small drill before you use the saw. That way you won't be trying to drill a pilot hole down a saw cut if the hacksaw doesn't work.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Raffles]

You're not too far from me.
If you tire of attempting to remove what's left of that screw or balls-up the job then simply remove the footrest hanger from the bike and bring it to me. I'll have it out in less than 10 minutes.
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A good loser will always be a loser.

[alithehat]

Thanks for that mate - Will keep you posted!