250R swing arm pivot bolt removal

[DonDDR]

Its stuck in there. The previous owner wanted it out too, the end is mushroomed over and hitting on it does nothing. I think its stuck in the bearings, as it turns freely. Anyone conquered this problem??? Thankx.

[viper_11111]

Sorry to say I had this problem as well. I ended up having to use a sawzall on both sides just to free the swingarm from the bike. Then we used a welding torch and lots of banging to finally destroy what was left of the bolt in order to get it out.

Of course this destroyed the ends where the dust covers went so we then had to build those up by brazing and filing. This worked well.

The last problem was a small amoutn of honing to clean up the area where the bearings went. Since things weren't exactly square anymore, the pivot pin was then binding up. A little more creative metal work and it now fits and rotates perfectly. If it wasn;t for the metal shop at work, I would never have been able to do all of this.

Basically my recommendation is to buy a new swingarm on EBay. You will have to cut the old one off which will destroy the dust caps.

Also, I believe even the manual recommends removing the bolt once a year or so and re-greasing it.

William

[Mobular]

I've drilled out the ends of an offending bolt to the point that it's so thin I can just crumple the remaining ends of the bolt and use a press to get the rest of the bolt out of the swingarm. When re-installing a new bolt ALWAYS use a good marine grade anti-seize lube. I cannot stress this enough! Th estuff is magic. You'll never have the problem again!

[atc86r]

when you put it back together use helm bushings and a 400ex swingarm bolt.

[wizzard]

you will need a torch or a drill

[BLAZERONE22]

I'm in the same boat, I'm going to drill the ends, sounds reasonable/