stuck swingarm bolt

[mike81]

I was hoping to get a lot done on my 81 XS650 this weekend. Removed the rear wheel to take to a shop to have the new tire mounted and balanced tomorrow AM. I was also planning to install new bronze swing arm bushings and maybe finish the dual disk installation.

I cannot get the swing arm bolt to budge. After removing the nut and grease zerk on the right side, I've been tapping with rubber mallet then a steel hammer. No go. As far as I can see inside the right side zerk hole, there is powdery red dust - dried grease. I just noticed that the grease zerk on the left side was missing.

I've had the bike for over 8 years, working on it only occasionally. Since I've had it it was always stored inside. Only 12K on the odo. It ran (poorly) when I got it, and I've never had it on the road, tho I hope to this year.

I sprayed some liquid wrench in both sides of the bolt, but a lot of it just runs out again. I spray more before I turn in, and maybe it will loosen over night. My other thought is to install the zerks, pump it with grease, and then work the swing arm up and down a lot.

Suggestions very welcome, thanks!

[gruff54]

I've had some that tried my patience, but I always got 'em out. Maybe they weren't that bad? Solutions I've heard were beat it into submission with a hammer, cutting the bolt between the swingarm and frame, and think I remember someone saying they had to put the frame w/swingarm in a hydraulic press. I'd suggest keep at it with a hammer and penetrating oil. Pound on it, let it soak overnight, repeat. Hopefully you'll get it sooner rather than later. You may want to locate a replacement bolt as there's a chance yours may get damaged. hth

Mike

[mike81]

I got it. Lots of liquid wrench and patience. And wacks of the hammer. That thing was STUCK. I did wind up deforming the threaded end with all the hammering. Once I had driven the bolt out far enough to get the 'faces' of the left side of the bolt clear of the boss that keeps it from rotating, an open end wrench and a bar gave leverage to rotate it. It took some time. Back and forth, eventually round and round. Once the threaded end was pounded into the frame, I used a 12 inch socket extension as a drift.

What a relief! Not sure if the bolt tube is serviceable. They are currently out of stock at Mike's.

[mike81]

Update. The bolt tube was also difficult to remove. An old 3/8 socket served as a hammering surface for the bolt tube, and putting it on the 12 inch socket extension allowed me to drive the bolt tube out of the swingarm. It was in pretty rough shape. The 12 inch socket extension also served as a drift to get the plastic bushings out.

I installed a grease zerk midpoint, and cleaned and touched up the swing arm with some high temp blank paint. Must order parts.

I also spent a lot of time getting the gasket off the engine at the sump strainer mounting point. Installed new sump strainer (old one looked intact at first but did have a tear as I understand many early ones did). Cleaned upper filter and added oil.

Mounted new shocks.

[mike81]

Update

Installing the brass bushings sure looked easy enough on the U tube video. For me it wasn't.

I did have the brass bushings in the freezer overnight, and used a heatgun to warm up the swing arm tube. It went in with the help of many wacks of a rubber mallet, but only so far. Liquid wrench and light oil were added, and it went in a few MM more with a lot more wacking. My forearm ached.

Then I thought of using a press. I found a 1 foot length of 3/8 allthread, and searched all over until I found some sufficiently wide, heavy washers that spanned 90% or so of the face of the bushing. It still took a good amount of effort, and I worried about stripping the threads, but it worked! No marks on the bushing face, either.

I felt so satisfied - and tired - that I decided to call it quits for the night and have a beer.

Cheers!