swing arm bolt won't budge >:( - 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 16 Old 03-22-2017, 07:10 PM Thread Starter
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Angry swing arm bolt won't budge >:(

Hi, i'm trying to remove the main swing arm pivot bolt from my 1990. It spins but it doesn't give the slightest indication that it is meant to slide out, even a millimeter. I hit it with an impact wrench, an air hammer, a torch, PB blaster, ~30 minutes of 10lb sledgehammer-ing (the end is mushroomed nicely now, and everything around it is smashed up pretty good.) Tried to get a sawzall with a metal cutting blade in there but there isn't any room. Next is grinder, or cutting torch, try to cut it on the inside without destroying the swing arm, then put the damn thing in a hydraulic press... or buy a new swing arm, at this point I don't care.

It does slide out right?? No hidden c-clips or anything???
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post #2 of 16 Old 03-22-2017, 09:41 PM
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Yes it does slide out; unfortunately this is a very common outcome when the pivot bolt hasn't been removed and lubed regularly. It seems you've tried most of the common methods; people have had to cut them out. The last one I recall hearing about they sacrificed the pivot linkage.

Good luck,
Dave
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post #3 of 16 Old 03-24-2017, 07:36 PM Thread Starter
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Ok. I'm going to give drilling a try before I start cutting it up.
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post #4 of 16 Old 03-24-2017, 08:42 PM
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Originally Posted by rhubic90 View Post
Ok. I'm going to give drilling a try before I start cutting it up.
rhubic90,
I read that, You do have access to an air hammer. Take a pause, that swingarm pivot has potentially been in there 27 years already!

Can you actually drill 14 inches of swingarm shaft out? I wouldn't want to even attempt it!

PB Blaster, soak 8 hours, air hammer From the Left.
PB Blaster, soak 8 hours, air hammer From the Right.
Repeat! It will eventually start to move.
Patience IS a virtue, in these cases.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
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post #5 of 16 Old 03-24-2017, 09:47 PM Thread Starter
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Originally Posted by pdwestman View Post
rhubic90,
I read that, You do have access to an air hammer. Take a pause, that swingarm pivot has potentially been in there 27 years already!

Can you actually drill 14 inches of swingarm shaft out? I wouldn't want to even attempt it!

PB Blaster, soak 8 hours, air hammer From the Left.
PB Blaster, soak 8 hours, air hammer From the Right.
Repeat! It will eventually start to move.
Patience IS a virtue, in these cases.
I got 1.5 inches on the left side already. I figure if I could drill a few inches on each side, I can get things apart and work on them better. Yeah it will eat up some drill bits $$, no doubt.

Ok I'll try the PB blaster again. I'm confused as to where it has rust-welded and why it can still spin. Is it where it goes through the motor?
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post #6 of 16 Old 03-25-2017, 11:13 AM
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Originally Posted by rhubic90 View Post
I got 1.5 inches on the left side already. I figure if I could drill a few inches on each side, I can get things apart and work on them better. Yeah it will eat up some drill bits $$, no doubt.

Ok I'll try the PB blaster again. I'm confused as to where it has rust-welded and why it can still spin. Is it where it goes through the motor?
The fact that the swingarm pivot goes thru the engine is why I didn't/don't think that drilling the ends off is a very good idea.
One may have to remove the engine to finishing drilling the rest of the shaft out.
I do not know. I have not had this challenge, yet!

The shaft could be rusted into the steel inserts of the engine case, those inserts could be forced to rotate. The shaft could be rusted into the hardened insert sleeves thru the needle bearings of the swingarm. Could be rusted into all 4 or only 1.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.

Last edited by pdwestman; 03-25-2017 at 11:19 AM. Reason: added text
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post #7 of 16 Old 03-25-2017, 02:40 PM Thread Starter
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Actually trying to get the engine out is what started this. Everything went fine until this last bolt!
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post #8 of 16 Old 03-25-2017, 04:37 PM
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Originally Posted by pdwestman View Post
.........................
The shaft could be rusted into the steel inserts of the engine case, those inserts could be forced to rotate. The shaft could be rusted into the hardened insert sleeves thru the needle bearings of the swingarm. Could be rusted into all 4 or only 1.
Yes, there are several bearing sleeves/inner races with spacers between them forming a solid sleeve around the shaft. They all seem to rust to the shaft if not lubricated within a couple of years after new.

Pdwestman is right. It takes lots of penetrating oil and heat and impact jarring to help it penetrate and PATIENCE. Then more of the same. Then wait a day and more of the same. Several here have done this for many days before succeeding. The older the rusty shaft, the longer it takes.

I used a brass drift pin to keep from buggering up the threads. When you reassemble it use plenty of anti-cease.
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post #9 of 16 Old 03-25-2017, 04:40 PM
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Quote:
Originally Posted by pdwestman View Post
.........................
The shaft could be rusted into the steel inserts of the engine case, those inserts could be forced to rotate. The shaft could be rusted into the hardened insert sleeves thru the needle bearings of the swingarm. Could be rusted into all 4 or only 1.
Yes, there are several bearing sleeves/inner races with spacers between them forming a solid sleeve around the shaft. They all seem to rust to the shaft if not lubricated within a couple of years after new.

Pdwestman is right. It takes lots of penetrating oil and heat and impact jarring and PATIENCE. Then more of the same. Then wait a day and more of the same. Several here have done this for many days before succeeding. The older the rusty shaft, the longer it takes.

I used a brass drift pin to keep from buggering up the threads. When you reassemble it use plenty of anti-seize.
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post #10 of 16 Old 03-25-2017, 04:57 PM
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Actually trying to get the engine out is what started this. Everything went fine until this last bolt!
Oh! Bummer!
About the only thing we can do for you now is cross our fingers and hope for good luck on your part.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
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