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  1. #1
    Senior Member balto charlie's Avatar
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    stuck bar end shifters

    Hey folks: I am almost finished stripping a $40 thrift store special. Bought it mainly for the spacial TA triple crank and shim 600 comps. Anyway the bar ends have been messed with and it appears that the allen head is "rounded" out. Should I drill it out or not waste the time. Any other way to remove stripped allen heads. If I drill them out will the rest be salvageable. Will I only have to replace the 6mm allen screw/bolts?? Thanks Charlie

  2. #2
    hello roadfix's Avatar
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    Instead of drilling them out and risk damaging the the shifter pods, I would slit (length wise) that portion of the handlebars where the shifters are inserted using a Dremel tool.
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  3. #3
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    An Easy-out is the usual cure but the Shimano bar end shifters I'm familiar with require that you "tighten" (i.e. turn clockwise) the bolt to loosen the pods so an Easy-out might not work. The recommendation to cut off the handle bar ends and slit them to free the pods might be the most functional solution.

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    Senior Member balto charlie's Avatar
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    Wow that was fast. Love this group. Sounds like a plan. The dremmel it is. Wasn't gonna keep the bars. I'm putting on moustache Mungos. Thanks guys, Charlie

  5. #5
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    have you tried putting the shift lever back on, and turning it... i want to say clockwise, but i forget which way the trick works. if the bolt's rounded out, it probably has been tried and won't work, but certainly doesn't hurt.

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    Quote Originally Posted by dafydd
    have you tried putting the shift lever back on, and turning it... i want to say clockwise, but i forget which way the trick works. if the bolt's rounded out, it probably has been tried and won't work, but certainly doesn't hurt.
    .....that's an even better idea...
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  7. #7
    Senior Member Deanster04's Avatar
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    Last summer I rebuilt a friend's Stella that was left out in the weather for most of the 30 years he had the bike. He had some Shimano friction shifters. I had good luck rebuilding them and they work well. I used a lot of Magic Mystery Oil a penetrating oil to remove all the rusted nuts and bolts. The bike came back surprisingly well and all the bearing surfaces were in tact. Good Luck

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    Senior Member balto charlie's Avatar
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    Quote Originally Posted by dafydd
    have you tried putting the shift lever back on, and turning it... i want to say clockwise, but i forget which way the trick works. if the bolt's rounded out, it probably has been tried and won't work, but certainly doesn't hurt.
    I can spin the entire unit but can't get it out. Perhaps some penetrating oil to ease it out. Haven't cut the bars yet. I'll play with it some more. Charlie

  9. #9
    Perineal Pressurized dobber's Avatar
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    Have you tried giving the bolt a couple of taps? If these are steel bars you may have a bit it corrosion holding things together.
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