DT250 Tracker

Mr Bernzo

Member
I guess I am at proof of concept stage now.
Wheels have been built and fitted, suspension upgraded, later model front end fitted with disc brake, 12v conversion competed, 12v lighting working.

Now I know everything is working it's time to go through the wiring from front to back, check and replace any suspect connections, wires and insulation. Route all of the wiring properly and tidy it all up.

The plan is to get this old beast roadworthy and registered before I strip it down and get the frame powder coated etc.
Still to go before registration: speedometer, rear brake switch, new front brake line, fix front brake switch, front mud guard, hand grips, fit seat, sort out steering stops and possibly a baffle for the exhaust. Will also need to review carb jetting.

Feels like I am finally making some progress!


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Mr Bernzo

Member
Test ride completed.
Runs well and selects all gears.
Still a lot of work to do, feels nice to actually ride it though.
Ordered the Speedo and swing arm bushes today.
Hopefully get a new braided brake line tomorrow.


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Mr Bernzo

Member
New brake line was made up yesterday, Speedo arrived today and seat has been ordered. Getting close now.

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Mr Bernzo

Member
New pads, braided line and painted parts. Hopefully the old girl will stop now!


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Mr Bernzo

Member
When that job you expect to take half an hour takes a lot, lot longer.

Trying to replace the swing arm bushes but can't get the pivot bolt out.

It's frozen in place. The nut came off easy. Tried whacking it withe 3 hammer, each one bigger than the last. No joy.

The bolt head is round so I can't get a socket and bar on it to lever it free. The hole is the bolt head is not large enough to get anything in that won't bend..... Tried that already.

Any ideas?

Going to try to buy 2 thin 12mm nuts that it can lock together on the thread then try turning the bolt next.

Or maybe some heat?


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Pete12

Member
Wow, that looks suspiciously like a rear axle for the swing arm bolt. Regardless, do what Brodie suggested but if you don't have any luck there you will probably need to get a hacksaw blade between the swing arm and frame on both sides and cut the bolt off. You will then be able to push it out with a press.
 

Mr Bernzo

Member
Pete12 said:
Wow, that looks suspiciously like a rear axle for the swing arm bolt. Regardless, do what Brodie suggested but if you don't have any luck there you will probably need to get a hacksaw blade between the swing arm and frame on both sides and cut the bolt off. You will then be able to push it out with a press.
Yes, it does look like the rear axle from this this bike. Cutting will be last resort. Hopefully heat and a slide hammer will work.

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Mr Bernzo

Member
Had some time tonight and had another crack at the swing arm pivot.
I started with a rudimentary press that I dreamt up and some heat. Didn't achieve much.
Moved onto a home made slide hammer.
A lot more heat and some slide action did nothing either.
I have managed to get the pivot Bolt to turn easily now though. I can also now pump more grease into the nipple.
Thinking I might use the air impact gun on it tomorrow and turn it some more, grease, turn, grease turn......
I am sure to piss the neighbours off if I fire up the air compressor after 10pm.
Slow progress.


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Mr Bernzo

Member
No movement on the pivot bolt yet, seat base turned up today though.
Will take some work to fit it up!


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Mr Bernzo

Member
Still no good on removing the swing arm pivot.
I drilled and tapped a hole in the head of the bolt. Made a slide hammer from M6 all thread and a big lump of steel.
I got no where. The nuts I had locked on the all thread stripped off after about 10 slides.
Not sure where to go from here.
Might need to strip the whole bike down to the frame and try pressing the bastard out or as a last resort, cutting it out.


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Pete12

Member
As the bolt is stuck in the swing arm you should be able to jack apart the two frame rails enough to get a hacksaw blade in there and cut the bolt off on both sides. The bolt will be fairly soft and a bottle jack with packers will get the rails apart. It's really not that big of a job, and a lot easier than stripping it all down and manhandling it in a press, particularly as you'll be pressing into the swing arm plates.
 

XS750AU

Member
Hi Bernie
I have been thinking about your "issue". Short of cutting the bolt, there could be some hope using a modification to your earlier attempt using the home made "screw press".
The force from your screw press is just flexing the frame. If you can anchor to the opposite side of the frame and then you will eliminate any flexing and the force will go directly into the pivot bolt. You would also need to use a lot heavier cross brace than the 3mm angle (guess) that you used in your first attempt. You need to eliminate flex.
Second idea is lie the bike on it side. Use a piece of 30mm tube (or there abouts) that pivot bolt round head can slide through and long enough to bottom out on the frame pivot bracket and shed floor. The threaded end of the pivot bolt would be pointing up, and then hit it with a BBH using a soft drift. This method also eliminates flex.
Heat on the engine pivot area will help for both methods.
Good luck.
 

Mr Bernzo

Member
XS750AU said:
Hi Bernie
I have been thinking about your "issue". Short of cutting the bolt, there could be some hope using a modification to your earlier attempt using the home made "screw press".
The force from your screw press is just flexing the frame. If you can anchor to the opposite side of the frame and then you will eliminate any flexing and the force will go directly into the pivot bolt. You would also need to use a lot heavier cross brace than the 3mm angle (guess) that you used in your first attempt. You need to eliminate flex.
Second idea is lie the bike on it side. Use a piece of 30mm tube (or there abouts) that pivot bolt round head can slide through and long enough to bottom out on the frame pivot bracket and shed floor. The threaded end of the pivot bolt would be pointing up, and then hit it with a BBH using a soft drift. This method also eliminates flex.
Heat on the engine pivot area will help for both methods.
Good luck.
Thanks, you read my mind. I have tried pressing the bolt out with M12 thread and a 12mm steel plate either side with a tube over the bolt head. Still no good. The next move is as per your suggestion with the bike on its side, tube over the bolt head and seated on the garage floor. Then the big hammer comes out.....

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