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Teeps
| | Posted on Tuesday, July 04, 2006 - 02:12 pm: | 
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Rhinowerx Posted on Tuesday, July 04, 2006
Update:
The bike had already been sent out to a specialty workshop (TapEx?) to have the broken bolts removed.
TapEx in Gardena, CA, uses an E.D.M. process to burn the original bolt out of the casting. This process does not damage the original threads. Will be good as new when they get done...
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Rhinowerx
| | Posted on Friday, July 07, 2006 - 12:57 am: |
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Checked in again today on the status of the repairs. Bolts have been removed and replacement sidestand and bolts have been ordered, as well as replacement parts for the damaged hand guard and hard bag lid.
In talking to the service guy, he mentioned that the bolts ordered are in fact grade 8, however he was unsure if they were any different than those that had originally been installed. The sidestand appears to be the new part previously mentioned.
For now though, it's the hurry up and wait game - for the parts to arrive that is.
Something else I went ahead and did; I ordered a Condor Pit Stop stand. I figure the sidestand set up lasted me about 10 months/7500 miles - with the Pit Stop stand, I wont have to keep the bike on the sidestand while it's at home, parked in the garage. Hopefully, the Pit Stop stand will help extend the 'life' of the side stand somewhat - or at least long enough until there's a recall on the bolts...
Cheers
-Jack |
Whodom
| | Posted on Friday, July 07, 2006 - 10:32 am: |
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One thought for anyone who is in the process of replacing the attachment bolts would be to use Belleville spring washers. These are conical-shaped washers that will maintain the pre-load on the bolts even if they stretch. These have been used in some really arduous industrial applications over the years (keeping steam locomotive frames together for instance) and would probably work well in this application. Read more here:
http://www.bellevillesprings.com/39.pdf |
Teeps
| | Posted on Friday, July 07, 2006 - 10:50 am: |
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Whodom,
Since in this application, the bolts are threading into aluminum, is a belleville washer applicable? |
Whodom
| | Posted on Friday, July 07, 2006 - 11:05 am: |
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Teeps,
I'd think they'd still be usable since they'd be "seating" on the steel bracket for the sidestand. Several of the posts seem to indicate part of the problem is that the bolts either aren't sufficiently tensioned when they're first installed or that they lose tension over time. The Belleville washers would help that. |
Buelldyno_guy
| | Posted on Saturday, July 08, 2006 - 11:07 am: |
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This is posted in another thread, but we have now found the last three bikes we serviced to have loose pivot bolts. ... We will call Tech Support Tues. ... Terry |
Rhinowerx
| | Posted on Thursday, July 13, 2006 - 12:18 pm: |
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Just got the call from the dealership saying the bike is ready, and that they just got notice of the recall.
In talking with the dealership, it seems that they were instructed to use the OEM bolts. However, once I get the recall notice, if the bolts have indeed changed, they will go ahead and swap them out, together with any other parts that were upgraded.
At this point, I'm glad they were able to get the bike fixed in time for the trip up to Laguna Seca next week. 
The damaged bag lid is still on order, but the side stand and the hand guard have both been replaced.
Unless I can arrange to get there any earlier, I'll be picking the bike up on Saturday morning. 
Cheers
-Jack |
Xbimmer
| | Posted on Friday, July 14, 2006 - 12:56 am: |
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Teeps, Bellville washers are used in eight locations to secure my three case racks, all threading into aluminum. Everything is still secure after a 2k mile trip this past week, and I didn't use the suggested red Loctite.
I'd never seen a Bellville washer before I got my Buell, look better than the metric wave washers or sae split lock washers, how would they work I wonder with your Allen bolts?
Rhino, glad you're getting back on the road soon. You going Hwy 1 to Monterey? I was planning on returning to So CA via the coast, ran out of time. Been a long time since I rode Carmel to San Simeon. |
Teeps
| | Posted on Friday, July 14, 2006 - 08:46 am: |
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Xbimmer Posted on Friday, July 14, 2006 -
Teeps, Bellville washers are used in eight locations to secure my three case racks, all threading into aluminum. Everything is still secure after a 2k mile trip this past week, and I didn't use the suggested red Loctite.
Pulling threads from an aluminum bracket or body part is less serious than the engine casting. I was just wondering if you mentioned them from experience or engineering wisdom.
I'd never seen a Bellville washer before I got my Buell, look better than the metric wave washers or sae split lock washers, how would they work I wonder with your Allen bolts?
Interestingly enough, my '78 Maico 250MX used a stack of bellville washers, instead of coil springs for the clutch. The use of bellville washers for the clutch springs was probably not ideal, but the clutch assembly was sure compact.
As for my allen bolts; that whole discussion is moot.
Cheers, enjoy the ride!!!
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Jetjock
| | Posted on Monday, June 25, 2007 - 11:06 pm: |
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This is the most current posting I found searching for kickstand broken bolts. What is the latest to fix & keep this from happening again? I just broke mine last weekend on a 2007 Uly with 4400 miles. Dealer says parts are over a week away.  |
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