TZR 125 caliper?

[BIG ZOOK]

Hello all,anyone know if you can get a decent grip on the inside end of a bleed nipple ,if you split the front brake caliper?.cheers all,

[Billing]

I take it you've snapped the hex off of the outside part of the nipple? You might be able to use a stud extractor or you can drill it out and re tap the hole, but I don't think that you can get to the sub surface part of the nipple at all
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'84 TS50X, '91 TZR125, '89 CBR400RR, '91 VFR400R NC30, '98 R1
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[Teflon-Mike]

Bottom of the nipple is actually a point, and the hole underneath is tiny, so that when you screw it in, the point fills the hole closing it off against brake pressure.
So No, there is very very little chance you'll be able to get anything in there to grip it!
As said, normal way to tackle the rounded off bleed nipple is to first try a better pair of mole grips.... you cant round it any worse than it is already so what the heck.
If that fails or you have sheared the hex off, so theres nothing to gip at all, is to get an 'E-Z out stud extractor from your local motorfactors.
This is like a left handed corckscrew, and works like a self tapping screw. Basically you screw it into the hole in the nipple anti-click wise and IN THEORY the thread bites into the metal, and at some point the grip it has in the nipple will be more than the force needed to unscrew it, so the E-Z out will stop turning in the nipple and start turning the nipple, and as you are turning anti-clockwise it SHOULD screw out.
In theory.
In practice, 9 times out of ten, the E-Z out snaps!
And they are a bugger to get out of a hole!
Drilling is though your next step, and provided you can get or dont have, the E-Z out shaft still stuk in there, fairly easy to get a drill in and follow the hole, taking it out in stages until its all gone.
BUT....
You are drilling through steel, stuck in an aluminium casting. Use a hand drill and go slightly 'off' and you'll start chewing the caliper to bits.
Go through to far and you'll start drilling into the caliper housing, AND worse the fine galery beneath the bleed nipple.
And THEN once you have drilled the thing out, you need to het the hole tapped and helicoiled to take a new bleed nipple.
we are talking precission engineering here, in a crucial safety critical part of the bike, AND on a TZR125 you only have the one!
PERSONALLY.... I suggest you either scrap the caliper and get a new or 'good' second hand one.
OR take it to a proffessional machine shop for them to sort out for you.
Places that do engine re-conditioning and the like for the motor-trade normally do this kind of thing quite regularly, and dont charge 'a fortune' though that's a bit subjective.
I'd expect to pay about £25 to have the job done properly; thats a fair price for abouyt half an hour of skilled machine operator time & facilities. May sound a lot to get one screw out..... but then think about it.... try to DIY it and cock it up, you scrap a caliper, and have to get a new one anyway. Cock it up 'ish' use it, and then blow your fluid when the thread goes.... well THAT could scrap the bike and more.......
DONT fuck about when it comes to brakes, do it right, its NOT worth the risk.

[Odie]

You can get a banjo bolt with a bleed nipple built in if you have snapped the nipple off in the calliper.
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[gmanxiii]

If the hex bit has broken off then a cheaper and quick way to try is getting a screwdriver that is slightly bigger than the hole (talking less than half a mm) and tap it with a mallet into the hole with a hammer and try unscrewing it that way. The top of bolts is what the thread pulls against to tighten up, if the top of a bolt has gone then there is very little pressure on the threads. I've removed a couple of snapped bolts from an engine in a similar fashion after i overtightened and tore them off.
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