Swingarm bolt is stuck
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  1. #1
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    Swingarm bolt is stuck

    Hi All,

    I've recently purchased a KTM 525 XC 2009 ATV. After some riding and getting to the maintenance and changing of back bearings I found that the swingarm is cracked.
    I got the new swingarm and all the necessary parts, but I struggle like hell to get the swingarm bolt out.

    Steps I've taken so far:
    * spraying everything with a better WD40, which is called Vulcan(some Polish magic )
    * Heating the bolt, heating the frame where the bolt is holding
    * applying brute force on hitting the bolt with a 2Kg sledgehammer

    I've only spent one day on this issue so far.

    Can you please suggest me on how to get this one out?

    Thanks in advance!

    Best Regards

    Swingarm bolt is stuck-img_2652.jpg
    Last edited by swingarm; 04-21-2020 at 07:35 PM.

  2. #2
    Senior Member KTMATVHQ Member
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    That brand new swingarm you got will do the same thing at the cross brace. Sean at Braap motowerx came up with a fix that gussets it and extends the brace all the way through. Making for 4 welds and multiple gussets instead of the half ass work ktm did.
    Now for the bolt. Heat it real good and try an air hammer.
    Do not use sledge hammers and what not as you can very easily bend the frame or break the cases doing so.
    This is a common problem in Hondas. Is what I found to work best it draining the oil and gas out of the machine and tipping it on its side.
    Then I spray the penetrant lube on the one saide and have gravity force it down, I take a heat gun and blast it while I’m spraying it. Then I let it sit for a day, spraying it more every chance I get. Then I do that other side. After that I heat it all up and get it out with an air hammer. put the swingarm nut back in the bolt so you don’t destroy the threads

  3. #3
    Senior Member KTMATVHQ Member
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    The pictured item is my own. I can get more pictures if you like. Highly recommend having this done.
    If you don’t. I might by your broken swingarm.
    KTM Swingarm Gusset / Repair Service

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  5. #4
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    Thanks for your suggestions! I’ve done one side of spraying now, will do another side when I’m in the garage next time.
    I will post a picture of where the crack appeared, I didn’t see that place on your pictures. Maybe you can suggest something on this oneAttachment 22086

  6. #5
    Senior Member KTMATVHQ Member
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    I've seen this problem before, especially with Honda 250Rs. If it is really stubborn people hammer and cut, and end up damaging the frame. But maybe you can rig a hydraulic press to push it through. Fab up some kind of kind of fixture. Just an idea.
    2008 KTM 525 XC
    2009 KTM 505 SX

  7. #6
    Senior Member KTMATVHQ Member
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    Quote Originally Posted by swingarm View Post
    Thanks for your suggestions! I’ve done one side of spraying now, will do another side when I’m in the garage next time.
    I will post a picture of where the crack appeared, I didn’t see that place on your pictures. Maybe you can suggest something on this oneAttachment 22086
    This image won’t load. So I can’t see it.
    Hydraulic press would have to be 100% true or it would likely bend the frame.
    If all else fails. You’ll just have to cut it out.

  8. #7
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    Adding the picture of the crack again. I’ve removed all the liquids from the machine, put that on a side, hammered it down properly, but the bastard won’t move a mm.

    What do you mean by cutting it out? You mean drilling it out?
    Attached Thumbnails Attached Thumbnails Swingarm bolt is stuck-a2043596-491c-4451-bf65-060ed810faae_1587759917356.jpeg  

  9. #8
    Senior Member KTMATVHQ Guru
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    I've heard of people trying to pry gaps between the frame/engine/swingarm, getting in there with a sawzall blade, and cutting through the bolt and/or sleeves.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  10. #9
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    After 4 days of trying everything I could, I finally decided to cut the bolt where the gaps where visible. It feels fantastic!!! Adding the picture of removed engine and the part which is stuck like hell.
    Attached Thumbnails Attached Thumbnails Swingarm bolt is stuck-08fe6b81-d014-4190-b43f-53394ab0c11a_1588609912678.jpeg   Swingarm bolt is stuck-97fca785-0095-467b-979d-b761664adcb8_1588609940327.jpeg  

  11. #10
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    Got some more progress so far. @guad97, thanks for your suggestion, I've made gaps between all the parts and cut as much as I could to free up the engine from the swingarm.
    Now I'm stuck at removing the remaining part of the bolt from the engine. I've used a taper to insert bolts from both ends and hit on them from one side and the other, but that does not help. Maybe someone can suggest what to do next?
    Swingarm bolt is stuck-img_2779.jpgSwingarm bolt is stuck-img_2777.jpgSwingarm bolt is stuck-img_2776.jpg

  12. #11
    Senior Member KTMATVHQ Guru
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    I would get a piece of heavy wall pipe that is a little longer than the width of the engine case with an I.D. just bigger than the bolt O.D., a piece of all thread, nuts, and some heavy duty washers. Run the all thread through the pipe and the center of the bolt. Put a nut on the exposed engine case side and make sure it is no larger than the OD of the bolt. Might have to grind the corners off. Then start screwing down the nut on the pipe side while applying some moderate heat to the engine case. Should pull the bolt out of the engine and into the pipe. If you get it cinched down pretty good and it's not moving it might have to be drilled out so you don't bust the cases.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  13. #12
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    This is how it ended and that’s the new swing arm in place. Thanks to all for your help and suggestions
    Attached Thumbnails Attached Thumbnails Swingarm bolt is stuck-973dba06-832f-4871-b968-73e31727c247_1589811847595.jpeg   Swingarm bolt is stuck-c69b3c12-3ce3-49df-8ff6-ae3e07003f1b_1589811870052.jpeg  

  14. #13
    Senior Member KTMATVHQ Guru
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    Wow! I wouldn't have thought one could get so stuck that it would have to be drilled/machined out!
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  15. #14
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    Yeah, this was the last resort. Just before drilling, we did hit it hard and it went 1mm down and didn't move anymore... so drilling was an effective solution. After drilling till the middle, then it went out by just hitting on it. Not sure if it's possible, but feels like it was stuck in the dowel which is in the middle of the engine case(nr. 10 on the picture). Swingarm bolt is stuck-2020-05-18-21_02_04-ktm-525-xc-atv-europe-2009-engine-case-msp.png

  16. #15
    Senior Member KTMATVHQ Member
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    Makes sense as they might have rusted together.


 

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