Tank/Shroud Bolt Trouble

[Dirtbikindad393]

So New Years weekend I went to the track Friday for 6 hours trying out my new 50t Ironman sprocket. Loved it....then after riding I am transforming my bike to do 120 mile dualsport ride the next day. It was an all dirt dualsport ride.
I put my 14t countershaft on and then start putting on my dez tank because the longest stretch was 58 miles for gas. As I am taking the shrouds off one of the shroud bolts won't loosen. I try and try and then the keeper spins. I figured I would WD-40 it and get it in a while. I keep installing the dez tank and last thing is to get the bolt off so I can put the shroud on the big tank. No luck........I get frustrated and put the stock tank back on.

What am I going to do to get the bolt out and secure the keeper from spinning? Was thinking about grinding the head of the bolt off then drilling out the rest get the keeper out and epoxy it back in. I will be greasing the shroud bolts from now on too.

[crfjedi393]

Sorry, I don't have any advice as I've never dealt with that problem before. Have you ridden in any salt water or anything? I have never greased the shroud bolts but it sounds like a good idea now.

[Dirtbikindad393]

Originally Posted by crfjedi393

Sorry, I don't have any advice as I've never dealt with that problem before. Have you ridden in any salt water or anything? I have never greased the shroud bolts but it sounds like a good idea now.

No saltwater but I take off the shrouds every once in a while toclean better and the keepers get water in them. The bolts are coated but are still steel and get kind of rusted. I will be greasing them from now on just like the chain tensioner bolts. What a pain in the I tell you especially out at the track trying to do this without all the tools in the garage.

[Florida 393]

Dane,
The spun female end in the tank is toast for now. Try getting a small straight slot screw driver or drift/chisel in between the tank and receiver to hold it. I have done this on John's Suzuki. There is a means to reinstall and adhere the stock receiver I have read, do a search here and at TT for this. Best of luck. The dielectric differential between the brass insert on the tank and the probably zinc coated steel or aluminum screw did the bonding and soap from cleaning will seep along the threads and form an adhesive.

Bill

[longwoodklon]

Originally Posted by Dirtbikindad393

No saltwater but I take off the shrouds every once in a while toclean better and the keepers get water in them. The bolts are coated but are still steel and get kind of rusted. I will be greasing them from now on just like the chain tensioner bolts. What a pain in the I tell you especially out at the track trying to do this without all the tools in the garage.

Can you maybe jam a tool between it and the tank, just enough to keep it from spinning while you take the bolt out? I'd think with the other bolts out, maybe you could move the shroud around enough to get behind it. Or maybe putting pressure on the keeper, by pulling on the shroud, will allow the keeper to stay in place just enough that you can remove the bolt.
Other than that, you're idea would work. Or just cut the shroud off....... (I'm only half joking)
Never had that happen, but just learned the hard way about the chain tensioner bolts, why didn't you warn me . Luckily got it out without stripping the swingarm threads, but I'll tell you I was lucky on that one. So now I guess I just gotta spray lube on the chain tensioner bolts AND the shroud bolts.
/Mike

[Dirtbikindad393]

Originally Posted by longwoodklon

Can you maybe jam a tool between it and the tank, just enough to keep it from spinning while you take the bolt out? I'd think with the other bolts out, maybe you could move the shroud around enough to get behind it. Or maybe putting pressure on the keeper, by pulling on the shroud, will allow the keeper to stay in place just enough that you can remove the bolt.
Other than that, you're idea would work. Or just cut the shroud off....... (I'm only half joking)
Never had that happen, but just learned the hard way about the chain tensioner bolts, why didn't you warn me . Luckily got it out without stripping the swingarm threads, but I'll tell you I was lucky on that one. So now I guess I just gotta spray lube on the chain tensioner bolts AND the shroud bolts.
/Mike

I have tried that jamming something behind it already.

I would not use a spray lube such as WD-40, I would use real grease especially on the chain tensioner bolts in the swing arm. There is no substitute for grease there. Sprays will dry up and be washed off especially if you use a spray washer to clean.

[KKXR400R]

Dane,
Hey buddy sorry to hear about the tank. This just happened to me a few weeks ago when I switched to a dez tank. I ended up taking a hacksaw blade, taped up one end and hacked the bolt off between the shroud and the tank. The tank survived pretty well as I was really careful of scuffing it with the blade. I'm going to be trying a plastic based epoxy pretty soon so I'll let you know. I know some of bolts may be hard to get to with some of bends but its worth a try. Which shroud bolt is frozen? Maybe post a pic? good luck

-Kevin-

[basanch73]

Sorry to here about the tank. I always apply neverseize paste to all bolts, screws and nuts that contact a dissimiler metal. You've probably noticed it on the steel bolts that bolt your sprocket to the aluminum hub. It can get ugly if left alone too long. I wouldn't recommend oil, as it might cause the screws to become loose and fall out during a ride without notice. As an airframe aircraft mech, I run into this dissimilar metal problem all the time.

To remove the screw in question, I would recommend finding something to put between the shroud and tank to keep the insert from moving as much as you can and then carefully drill only the head of the screw off if able. We use a Cherrymax bolt/insert remover for things like this. Basically once the head is off you screw the bolt remover onto the remaining screw and then squeeze it which draws the bolt and insert from the bonded area. In your case if you could get this screw head off and with some of the threads showing, you could screw a nut onto the existing threads and then get a nail prying tool of some kind to pry the insert and screw out as one. I only recommend this because jamming a screwdriver between the insert and tank could possibly crack the tank in the process. Just a thought from my experiences in the past.

Let us know how things go.

Brian

Originally Posted by Dirtbikindad393

So New Years weekend I went to the track Friday for 6 hours trying out my new 50t Ironman sprocket. Loved it....then after riding I am transforming my bike to do 120 mile dualsport ride the next day. It was an all dirt dualsport ride.
I put my 14t countershaft on and then start putting on my dez tank because the longest stretch was 58 miles for gas. As I am taking the shrouds off one of the shroud bolts won't loosen. I try and try and then the keeper spins. I figured I would WD-40 it and get it in a while. I keep installing the dez tank and last thing is to get the bolt off so I can put the shroud on the big tank. No luck........I get frustrated and put the stock tank back on.

What am I going to do to get the bolt out and secure the keeper from spinning? Was thinking about grinding the head of the bolt off then drilling out the rest get the keeper out and epoxy it back in. I will be greasing the shroud bolts from now on too.

[Dirtbikindad393]

Originally Posted by basanch73

Sorry to here about the tank. I always apply neverseize paste to all bolts, screws and nuts that contact a dissimiler metal. You've probably noticed it on the steel bolts that bolt your sprocket to the aluminum hub. It can get ugly if left alone too long. I wouldn't recommend oil, as it might cause the screws to become loose and fall out during a ride without notice. As an airframe aircraft mech, I run into this dissimilar metal problem all the time.

To remove the screw in question, I would recommend finding something to put between the shroud and tank to keep the insert from moving as much as you can and then carefully drill only the head of the screw off if able. We use a Cherrymax bolt/insert remover for things like this. Basically once the head is off you screw the bolt remover onto the remaining screw and then squeeze it which draws the bolt and insert from the bonded area. In your case if you could get this screw head off and with some of the threads showing, you could screw a nut onto the existing threads and then get a nail prying tool of some kind to pry the insert and screw out as one. I only recommend this because jamming a screwdriver between the insert and tank could possibly crack the tank in the process. Just a thought from my experiences in the past.

Let us know how things go.

Brian

Thanks Brian the bike has been gone to the suspension shop for a week and now we have our first dez race of the 2007 season this weekend. I am leaving well enough alone and will work on it next week. I will try to remember to take pics and post them.

Dane

[basanch73]

Sorry to here about the tank. I always apply neverseize paste to all bolts, screws and nuts that contact a dissimiler metal. You've probably noticed it on the steel bolts that bolt your sprocket to the aluminum hub. It can get ugly if left alone too long. I wouldn't recommend oil, as it might cause the screws to become loose and fall out during a ride without notice. As an airframe aircraft mech, I run into this dissimilar metal problem all the time.

To remove the screw in question, I would recommend finding something to put between the shroud and tank to keep the insert from moving as much as you can and then carefully drill only the head of the screw off if able. We use a Cherrymax bolt/insert remover for things like this. Basically once the head is off you screw the bolt remover onto the remaining screw and then squeeze it which draws the bolt and insert from the bonded area. In your case if you could get this screw head off and with some of the threads showing, you could screw a nut onto the existing threads and then get a nail prying tool of some kind to pry the insert and screw out as one. I only recommend this because jamming a screwdriver between the insert and tank could possibly crack the tank in the process. Just a thought from my experiences in the past.

Let us know how things go.

Brian

Originally Posted by Dirtbikindad393

So New Years weekend I went to the track Friday for 6 hours trying out my new 50t Ironman sprocket. Loved it....then after riding I am transforming my bike to do 120 mile dualsport ride the next day. It was an all dirt dualsport ride.
I put my 14t countershaft on and then start putting on my dez tank because the longest stretch was 58 miles for gas. As I am taking the shrouds off one of the shroud bolts won't loosen. I try and try and then the keeper spins. I figured I would WD-40 it and get it in a while. I keep installing the dez tank and last thing is to get the bolt off so I can put the shroud on the big tank. No luck........I get frustrated and put the stock tank back on.

What am I going to do to get the bolt out and secure the keeper from spinning? Was thinking about grinding the head of the bolt off then drilling out the rest get the keeper out and epoxy it back in. I will be greasing the shroud bolts from now on too.