Can't remove Clutch pivot bolt lock nut!

[ninja98r]

Trying to install shorty's. Having a hard time removing the clutch pivot bolt as the bottom nut will not come off. I am keeping the bolt from turning using a wrench while at the same time using a ratchet on the nut. The bolt is steady and the nut turns and turns but doesn't make it's way off the bolt. It won't tighten or loosen. Any tips or suggestions out there? Already got a replacement bolt and nut from the dealer as I anticipate I will have to butcher the current. Thinking about the best way to get the nut off without damaging the handlebar.

[Motofool]

Use a small screwdriver to force the nut out while you rotate the nut with a wrench; it will catch the thread of the bolt eventually.

The bolt screws in the thread of the aluminum support, which you will need for the new one: be very gentle with that one.

The nut is just a counter-nut.

The clutch switch is very fragile, removing it is better.

[ninja98r]

Thanks for the advice.

I have been removing the clutch sensor while attempting to remove the lock nut.

I did indeed try to wedge a small flathead albeit I was really trying not to scratch the support mounted to the handlebar. Perhaps I'll try again with more force.

I don't think the support will need to be replaced if I'm careful....? We'll see I guess.

I was also thinking of drilling or using a dremmel to the nut but will try to wedge it off while turning again first.

This was to be a simple mod!!! Only me!

Originally Posted by Motofool

Use a small screwdriver to force the nut out while you rotate the nut with a wrench; it will catch the thread of the bolt eventually.

The bolt screws in the thread of the aluminum support, which you will need for the new one: be very gentle with that one.

The nut is just a counter-nut.

The clutch switch is very fragile, removing it is better.

[Motofool]

Originally Posted by ninja98r

.........I was also thinking of drilling or using a dremmel to the nut but will try to wedge it off while turning again first.

You are welcome

Use something soft, like a plastic table knife instead of a screwdriver.
You don't need much force, only enough to force the nut to catch on the thread of the bolt.
Due to over-torquing, the threads of the nut or/and the bolts have been damaged on the section covered by the nut, which is basically spinning over the bolt now.

A Dremmel may work or not, because too much damage to the bottom section of the bolt means that the soft aluminum thread of the support could be damaged when that end goes up and through it (unless you make it smooth with a file first).

Just a couple of ideas.
Hope you can solve the problem soon.

[ninja98r]

Got my shorty's on finally!!

Happy to report that I was able to get the clutch pivot bolt and nut out
Tried and tried to wedge the nut off but was unsuccessful....

Ended up having to carefully drill out the bolt just enough to get the nut off.

Tip: The lever brackets are threaded. Make sure you loosen and remove the lock nut prior to the pivot bolt. I believe I broke the bolt thread covered by the lock nut by attempting to loosen the bolt first. The lock nut was preventing the bolt from lifting causing the thread to break.

[Motofool]

Did the thread in the bracket get damaged when you unscrewed the drilled bolt?

If yes, did you have to replace the bracket?

[ninja98r]

I managed to spare the bracket thread when removing the pivot bolt.
Albeit it was more snug trying to get the replacement bolt back in.

I was mindful when drilling out the bolt. Used two sized bits and made sure there were no protruding metal.

Thanks for the heads up on the risk.

Originally Posted by Motofool

Did the thread in the bracket get damaged when you unscrewed the drilled bolt?

If yes, did you have to replace the bracket?

[Motofool]

Originally Posted by ninja98r

Thanks for the heads up on the risk.

You are welcome