Clutch update

[Jersey Big Mike]

Guess what happened to me today! #$%%$$%^%%/_×$_^%$$:&^%<^%

Still need to take apart but 99% sure same issue. Why do these MFers have to break on a freakin road trip. Im getting sick of this shit.

I thought it was just me that had crap happen on road trips -- I feel your pain.
If it's clutch PM me I have some spare parts.

 

[roadie1389]

I have 04. Its pointing to the same broken bolt issue. Fixing it with a Shiner.

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[knothead]

I have 04. Its pointing to the same broken bolt issue. Fixing it with a Shiner.

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Hey roadie if u get a minute read my post #40 on this....ive fixed 4 bikes this way and all of them was 04 models including mine...

 

[pauldeepsea]

Ive missed this whole thread...it can be fixed i have fixed several and plus one of my on....the bolts best i remember is 5/16ths fine thread....i cant remember how long they are but go 1/4 longer so they protude the back side and put a nut on the back of everyone when u put it back together....the nuts will fit in the groove if not just buff to sides till it does...some holes may be screwed but thats ok u will have some holes the threads are still good...use them to align it up....once u get it all together tighten them up....take a tig rig and weld the nut to the bolt that will make them draw tighter....bolts never will back off again....if u ever have to spilt it back apart for any reason all u got to do is grind the weld on the nut till u see the weld is gone and the bolt will back out if not grind some more till the threads are clear of weld and back it out

That’s different, I am not sure I would do it but if it works for you. Imho I would clean the threads and use a grade 8 bolt, blue locktight and torque to spec..

 

[roadie1389]

Actually, they dont come loose. They are smashed on the back side at factory, at least this one was. Its they shear off. Not sure why it happens but Promo does not seem to make it anymore.... The threads are clean. Being its Easter nothing is open so will get new bolts tomorrow. I am curious what clutch they used in the new bikes.

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[Letbigdogintocanada]

Guess what happened to me today! #$%%$$%^%%/_×$_^%$$:&^%<^%

Still need to take apart but 99% sure same issue. Why do these MFers have to break on a freakin road trip. Im getting sick of this shit.

The original bolts weren’t hardened enough from what I found ,go with the best bolts for the sprocket ,it wasn’t even 8.8 grade

 

[roadie1389]

So I am not a fastener engineer so I have to take the word from the manufactures. According to the research I have been doing the socket cap bolts are suppose to be Grade 8/9 and widely used in this type of application. This is solely based on what I have been reading socket bolts are not marked the same as regular hex bolts so you have to read the manufacture data. BUT given how easy it was to drill out the bolts I do suspect that the original bolts are shit. I got new bolts today that claim to be Grade8. I am also looking at various clutch baskets as a replacement. The ones you see on JPCycles and like places are not meant for these bikes with higher HP/Torque output. I found a couple places and reached out to Bandit as well. We shall see.

 

[bdm7250]

So I am not a fastener engineer so I have to take the word from the manufactures. According to the research I have been doing the socket cap bolts are suppose to be Grade 8/9 and widely used in this type of application. This is solely based on what I have been reading socket bolts are not marked the same as regular hex bolts so you have to read the manufacture data. BUT given how easy it was to drill out the bolts I do suspect that the original bolts are shit. I got new bolts today that claim to be Grade8. I am also looking at various clutch baskets as a replacement. The ones you see on JPCycles and like places are not meant for these bikes with higher HP/Torque output. I found a couple places and reached out to Bandit as well. We shall see.

Where did you get the bolts? Just because they are stamped as grade 8 doesn't necessarily mean you have a high quality bolt. We have come across countless lots of garbage structural bolts (grade A325 and 490) imported from China with all the QC certificates. I would suggest that you ensure you're getting a quality product made in the USA. Also I personally would not go with a grade L9, although tensile strength is greater it is a far more brittle bolt, these are made for slip critical situations, if by chance the bolt does loosen up it is not as resilient in shear as the grade 8 and is more susceptible to breaking.