My bike repairs have had to take a back seat till this is sorted, so it's kind of urgent?

I was attempting to change the throttle cable (it snapped) on the lad's Suzuki GZ125 today (easy job, I hear you say?) and came up against a couple of problems....

Problem 1: One of the "pinch/clamp?" screws holding the r/h switchgear to the bars has rounded and so the screwdriver wont grip. I tried cutting a slot in the head with a junior hacksaw so I could try to turn it with a flat headed screwdriver but it still wont budge!

Problem 2: On removing the brake lever from the bars (to get the hacksaw in to cut the slot in the bolt on the switchgear), one of the pinch bolts sheared. There is about 1/4 inch of threaded bolt sticking out of the master cylinder.

I've soaked everything in Plus Gas and left it to soak in overnight to try to free things up a little. I'm thinking that my only remaining option is to drill them out????

Unless anyone can think of a better way? Do those extractor stud things work?

I've got the cordless drill on charge for the morning, just in case!

He's got his Part 1 motorcycle test booked soon, so I need to get this sorted.

Any helpful suggestions would be very much appreciated.

Thanks .... I know it's not a CBR issue, but really would welcome your help / comments. Then I can get on with sorting MY bike!

 

Two ideas

Prob 1 ......drill off the remainder of the head ...when free use a vice grip
to unbolt whats left .... use a proper penetrating oil

Prob 2 . drill a small hole in the remainder and take a "scarificial" torx head and drive it in tight ( hole needs to be smaller than the torx head by a smidgeon)
and see if she'll ratchet off .......again penetrating oil

Worth a shot......maybe

Step three ....... grab a six pack

 

Haha! Good advise matey ... that 6 pack sounds appealing!

I've try what you said in the morning .... thanks ... hadnt thought of that.

6 pack on stand by!

 

From experience the extractor tools work pretty good, since they work on reverse thread, so the harder you try to loosen the tighter they get. Although there are some pretty cheesy ones on the market. I am pretty sure Sproks method will work. Lots of PB blaster!! and Beer