Stuck pivot bolt - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 7 Old 10-14-2016, 09:40 PM Thread Starter
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Stuck pivot bolt

Finally got the dog bones off with a air impact gun. I'm still having trouble with the pivot bolt. I removed the nut but the pivot bolt isn't coming out. I even used a pipe and hammer trying to bang it out. It has been soaked in PB Blaster as well. Any one have any ideas?
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post #2 of 7 Old 10-15-2016, 08:07 AM
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Since you are working with a loose frame - know anyone with a press? Apply a little heat??

On a Wing and a KLR.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 7 Old 10-15-2016, 10:07 AM
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Quote:
Originally Posted by Johnnny13 View Post
Finally got the dog bones off with a air impact gun. I'm still having trouble with the pivot bolt. I removed the nut but the pivot bolt isn't coming out. I even used a pipe and hammer trying to bang it out. It has been soaked in PB Blaster as well. Any one have any ideas?
Johnnny13,
From the RH side of the frame, looking past the brake pivot area, do you see an 1/8th inch hole in the frame pivot pipe at about 8:30-9:00 position?
That is where the factory 'plugged-in' a stupid little zip-tie to hold the air box drain pipe, the battery vent hose and the fuel tank vent hose.

That is where the water gets into the pivot pipe and creates rust on the pivot bolt next to the linkage knuckle! Fill the internal area with PB Blaster.
Chances are that the far RH side near the footpeg mount has already been freed.
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post #4 of 7 Old 10-16-2016, 09:37 AM
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PB blaster, heat, and an arbor press should do the trick.

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #5 of 7 Old 01-26-2017, 12:10 PM Thread Starter
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We wound up cutting it and getting a used one on eBay. I'll be back to restoring the bike (currently stripped to the frame) in April.
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post #6 of 7 Old 01-26-2017, 07:41 PM
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For future reference the best penetrating oil I've ever used is chain lube.

I used it in a pinch once when it was all I had on hand, now it's my go to for any stuck fastener. Works amazingly well.
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post #7 of 7 Old 04-19-2017, 12:39 PM Thread Starter
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Thanks for everyone's help. I finally got the pivot bolt out of my bike. I took it to a local shop and they used a press and heat but only got it to move about 5 inches. I was able to cut the bolt on the left side first and then shift over the bearing sleeve to the left to cut the right side. I have a replacement pivot bolt and lever. This was a tough one to cut with a hacksaw.

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