Join Date: Jun 2009
Location: East coast North Carolina
Liked: 411 times
400EX Pivot bolt info
I am here to offer a little insight to my experience in removing a frozen swing arm pivot bolt on a 2006 TRX 400EX. After reading until my eyes hurt. I have come to the following conclusion. Honda did not think this area through very well. lol. After 2 days of spraying heating beating, Repeat ect ect, We were able to move the bolt a full 1/8" yes I said 1/8". lol. We broke out the last resort...the Die-Grinder with a cut-off wheel. Note: If you can't get the bolt to move a substantial distance in 8 or 10 blows with an 8lb. hammer it's not going to move. first we removed the subframe and shock, it makes all the room and easier to work... The first cut was made on the right side of the engine where the pivot bolt goes through the block (make all cuts while rotating the bolt), next we moved up as close to the swing arm on that side as possible, once you make that cut there will be about 1/4" of sleeve left to get off of the bolt, leave that for now.On the left side find you a small piece of wood another set of arms and a long prybar. take the wood and stick it just below the starter on the housing, take the pry bar and wedge it between the wood and frame now those other set of arms need to pry the motor towards the brake side just enough to get your cut wheel in there, make your cut rotate the bolt cut again and so forth until it breaks free. now Over to the left side take your cutter and cut around the edge of the dust cap like you are going to split it into 2 pieces ( you will have to rotate it too). after you cut through cut across it to remove the end closest to the swing arm. Now you have room between the frame and swing to cut the bolt. After you cut through that end remove the end of the bolt.
Almost done. grab the Swing arm and twist it upon the left side above the engine and out if your bearings are still inside you may have to pry it out. now that the swing arm is out of the way you can take a long rod and tap out the left over bolt from the engine, I was able to pry the remainding sleeve off of the right side and then remove the bolt head.
This is basically what we had to do in a nut shell, I do not recommend beating on the bolt for more than the amount I stated above. The reason why is after all that whailing we noticed that while we were beating the truth out of the bolt end we didn't realize we had actually bent the pivot gusset out about 3/8 or an inch on the brake side. SO don't do it. If you take your time and cut it out turn the bolt while cutting you won't hurt the case or anything in the area. I hope this experience will aid anyone else in removing their stuck pivot bolt, This method may work for other models but I really wasn't going to try it on the other quads in the shop..lol Good Luck.
PS. When you install the new bolt put a liberal amount of anti-seize on it, you'll love your quad later for it. lol
"MOOSE WAGON "
00 TRX400EX aka "MOOSE ROCKET"
91 TRX250X aka "MOOSE WAGON" RETIRED
96 Polaris 400L sport (Mrs. Moose Ride)
07 Suzuki LTZ250 (Sons)
96 Polaris 250 Trail Blazer (daughters)
06 TRX450ER aka === Under construction
Progress and Help
PM FOR MANUAL HELP
Last edited by TRX2fiveO; 12-05-2010 at 07:43 PM.