extracting broken bleeder screw

[catch2otwo]

So I got around to bleeding my front brakes on my tuono today. The head on the bleeder screw on the master cylinder broke off. So theres the body left inside the master cylinder. Any ideas on how to get it out?

I tried some bits that were made for extracting rounded out screws but all it did was eat away at the soft metal. I was thinking easy outs but I dont think there will be enough material left after drilling a hole big enough for the easy out bit. The local hardware store didnt have any easy out bits small enough.

[Frankienuckles]

try to remove it with an easyout. If it chews it up drill and re-tap up to the next larger size bleeder (sae thread maybe?) A little cobby, but much cheaper than a new master cylinder and once it's done you'll never be able to tell. Also make sure to get ALL of the metal chips and shavings out.

[catch2otwo]

what would be the best place to source a set of easy outs?

I found a used master for 70 shipped with the lever and resi. might go that route to get things up and running. but the bike will be down for the weekend, this blows

[Rambunctous]

I got some. But I am in Worcester.

[catch2otwo]

ha thanks dude, a touch too far. Would sears have small enough easy outs? or maybe home depot?

[The Snowman]

is there enough to slot it and take it out w/ a screwdriver?

[catch2otwo]

na chuck, almost all of it is inside the master. I tried tapping a small screwdriver in there hoping I could turn it out, but the metal is pretty soft. trying not to ruin the existing female threads

[Kurlon]

Reverse drill bit? Gotta be careful to avoid damaging the base of the hole though where the bleeder seals.

[andrew]

I have been able to drill a hole & then hammer a torx bit in there to get them out . But if you broke the head off I doubt it will work with out heat . Maybe , drill it . get a easy out or hammer a torx bit in . Hit it with a small torch to the aluminum . Its not going to take much .

[catch2otwo]

I was afraid to put a torch to it as I didnt know what kind of funky metal mix they make the master out of. Im quitting for tonight before I make things worse

[darkduc7]

holy crap, about a month ago i had this EXACT problem on my 749, which i believe has the same brembo mc's with the funky geometric resivoirs. the head of the bleeder screw snapped off, and then i couldnt get the body of the screw out with extractors cause the metal was too soft. i ended up using a large drill bit and carefully removed as much material as i could of the bleed screw so i could fit an allen key into the bolt that holds the resivoir to the mc. i then removed that bolt and was able to use vice grips on the other end of the bleed screw to back it out of that larger bolt. pm me if you have any questions, just be careful not to ruin the hex of the allen bolt when you drill

[catch2otwo]

holy crap, about a month ago i had this EXACT problem on my 749, which i believe has the same brembo mc's with the funky geometric resivoirs. the head of the bleeder screw snapped off, and then i couldnt get the body of the screw out with extractors cause the metal was too soft. i ended up using a large drill bit and carefully removed as much material as i could of the bleed screw so i could fit an allen key into the bolt that holds the resivoir to the mc. i then removed that bolt and was able to use vice grips on the other end of the bleed screw to back it out of that larger bolt. pm me if you have any questions, just be careful not to ruin the hex of the allen bolt when you drill

I dont think I have the same mc as your 749, I have the regular round resis. I know exactly what mc your talking about though. Im going to try getting an easy out in there. what a pain in the ass

[darkduc7]

hmm. i know the mc's on the rsv's are the same. anyhoo, good luck

[andrew]

What did you end up doing with this ?

[catch2otwo]

well after a few hours in my friends machine shop, MC won. could not extract the broken half of the bleeder screw. It was so stuck in there, that the easy out wouldn't tunr it, basically had to drill it all out threads and all. at that point we knew it was ruined. The way the mc is designed, there was not enough material there left to redrill and tap for the next size bleeder. So its now scrap. New mc will be here on thursday. New bleeder screw will have anti seize applied....

[Kurlon]

Or, just forgo the bleeder at the master? Weld over/epoxy/block off the busted bleeder port and run it. You have bleeders on the calipers, and can bleed at the master by letting the lever 'snap' back from a slight squeeze. The vibration will release air bubbles up into the reservoir, so you can visually see how much air is left in the line without having to pump any fluid out of the system. I do 90% of my brake bleeding via the lever now.

Edit: If you NEED a bleeder at the master, get a bleeder banjo bolt. : )