How do I get this bolt to come out?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by 4corners14, Apr 2, 2014.

  1. 4corners14

    4corners14 Been here awhile

    Joined:
    Oct 3, 2008
    Oddometer:
    771
    Location:
    Seattle
    any suggestions on how to break this axle adjustment bolt loose?

    [​IMG]

    I tried to heat it up.....it's rounding off the nut and it won't turn either direction. SUGGESTIONS? :ear :ear :ear
    #1
  2. scudrunner82

    scudrunner82 combustion addict

    Joined:
    Oct 6, 2012
    Oddometer:
    3,916
    Location:
    Catskill, NY
    Can you get a 3/8 drive impact wrench on it?
    #2
  3. wcohl

    wcohl Been here awhile

    Joined:
    Nov 12, 2008
    Oddometer:
    451
    Several ideas, but they are messy.

    Does your swingarm have a drain hole? The drain hole should be ahead of the weld where the extruded arm is welded to the machined axle block. I'm not as familiar with the bigger KTM's, but the 2004 and older smaller KTM didn't have a drain hole. The hole should be no larger than 1/8". When drilled the hole in my 2003, I was surprised at the amount of water that came out.

    If your bike has a drain hole, hang the swingarm axle block down and fill with penetrating oil. Let it soak for a while.

    If that doesn't work, drill out the existing bolt and retap for an oversize bolt.
    #3
  4. 4corners14

    4corners14 Been here awhile

    Joined:
    Oct 3, 2008
    Oddometer:
    771
    Location:
    Seattle
    [....the nut is attached to the slide that holds the axle. I can't see anyway to take the slide off.


    QUOTE=scudrunner82;23844004]Can you get a 3/8 drive impact wrench on it?[/QUOTE]
    #4
  5. CollinsB

    CollinsB Long timer

    Joined:
    Aug 17, 2003
    Oddometer:
    1,057
    Location:
    Orange Co., CA.
    I just dealt with this very problem a few days ago... Tried the torch, penetrating oil, etc. nothing worked and eventually had to drill it out. Starting with a small bit, and worked my way up. Took roughly 15 minutes to drill and re-tap. Not too difficult.
    #5
  6. HeatXfer

    HeatXfer Bad knees

    Joined:
    Feb 18, 2008
    Oddometer:
    801
    Location:
    S.F. Bay Area
    Try to do as little damage as possible.

    1st: Be careful with a torch and aluminum.

    2nd: Throughly wet the area with a 50/50 mixture of automatic transmission fluid and acetone.

    3rd: Get two small vice grips and clamp them to the bolt so that one tightens and one loosens. Set the jaws so they touch each other side by side.

    Now rock back and forth: loosen-tighten-loosen-tighten. Tiny movements at first. Keep the area soaked with the penitrent. The bolt will eventually start to move. Keep the swings small, you don't want to fatigue the bolt and break it; you want to finness it out.

    Be patient, it will take some time. It's possible the thread damage won't require drilling out. If you can grip the bolt on both sides of the threaded hole, that will help.

    Once it's out you'll be able to prepare the hole for a Helicoil insert.

    Good luck.
    #6
  7. 4corners14

    4corners14 Been here awhile

    Joined:
    Oct 3, 2008
    Oddometer:
    771
    Location:
    Seattle
    Inside the axle housing slide (orange) there's a c-clip holding the bolt to the slide....once I got the c-clip off the slide, the slide pulled off the bolt and I could get a socket on the nut. It was very tight but I eventually got it to back out. I'll tap and die the set and use some anti-seize this time!



    #7
  8. HeatXfer

    HeatXfer Bad knees

    Joined:
    Feb 18, 2008
    Oddometer:
    801
    Location:
    S.F. Bay Area
    Great!
    #8
  9. JohnnyWaffles

    JohnnyWaffles Been here awhile

    Joined:
    Jul 16, 2012
    Oddometer:
    301
    Location:
    Denver, CO
    Happy ending!:freaky
    #9