Stuck swingarm bolt on 1979 KZ650D SR model

Guys, I have tried heating it, hitting it, beating it, lubing it and the swingarm pivot bolt will NOT come out. It barely even moves. I think the bolt is fused to the inside pivot tube on the swingarm and I can't break it free. I need to get this swingarm off so i need help. Thanks in advance!!!

There has been talk of how useless the grease fitting is on the old swingarms. Makes me want to go out and grease mine up. Sorry to hear of you frustrations.

ten6 wrote:

Guys, I have tried heating it, hitting it, beating it, lubing it and the swingarm pivot bolt will NOT come out. It barely even moves. I think the bolt is fused to the inside pivot tube on the swingarm and I can't break it free. I need to get this swingarm off so i need help. Thanks in advance!!!

Here's the parts diagram for reference.

Question -- Is it that the nut#1 and cap#2 come off okay but the rest is all frozen together?

The nut is off...it just won't slide out...no matter what i do.

ten6 wrote:

The nut is off...it just won't slide out...no matter what i do.

Is it possible to get a socket on the bolt head and turn it? Then perhaps use an air-wrench to spin the bolt in hopes of at least partially freeing up some of the frozen parts in the inside assembly?

Could also remove the grease fitting and fashion a small tube or other fitting whereby PJBlaster (or similar liquid rust-busting product) could be allowed to continuously seep inside over a period of several days in hopes of partially loosening things up.

Am presuming already used a drift and really bfh in an effort to punch the bolt out from its threaded end. Could use a pipe over the bolt head between the swingarm and wall (to prevent any give), and then use a sledge-hammer and drift (same size diameter as bolt or slightly smaller) to attempt punching the bolt out toward the right hand side (through and into the pipe). Seems like something would have to give.

Remember to wear protective goggles and extra heavy thick padded gloves.
And, Don't Miss !

Good Luck!

I can spin the bolt head by hand with my fingers..it spins fine but it just doesn't move laterally. I don't think i can fit a sawzall blade between the swingarm end and the frame...

The swingarm pivot bolt has rust welded itself to the sleeve between the bearings. At this point it's virtually impossible to save the bolt for re-use.
Are you working on the bare KZ650 frame you picked up at Montpelier? Assuming it is bare frame, you can take it to someone that has a appropriately sized hydraulic press (a big one) and have them push the bolt out.

If no large hydraulic press is available, you might try cutting the head off the bolt (with a cutting torch or grinder) and working the bolt back and forth with a BFH, this should work sooner or later.

Another option is to remove the part of the bolt that goes through the frame on each side, either by drilling with progressively larger drill bits or an EDM (if you can find a machine shop with a large enough tank on their EDM to fit the frame), then drop the swingarm out of the frame. At that point you can tap the axle through one bearing thus driving the other bearing out, and you're home free (except for needing a new bolt, sleeve, and bearings/bushings.

I have a spare swingarm and pivot bolt off a disk brake 79 KZ650SR if you need them.

I will need those parts Steve...hang on to them for me.

ten6 wrote:

I will need those parts Steve...hang on to them for me.

Will do!

Got the front end off the 79 SR also if you need it, just don't have the wheels, took them to the scrap metal yard last week.

I got the swingarm off...I had to buy a 14" sawzall blade to get in from behind and cut between the swingarm and the frame...it sucked but it's done.