Looking for some ideas/help!

[RRRUFF]

A friend of mine has an 06k9. We have replaced his rear fender strut bolt several times. We have used the BDM recall bolts, and the most recent bolts were said to be the strongest bolts made by the bolt vendor. Here are some factors to consider.

1) Always the left rear strut bolt

2) Threaded hole in frame I had to drill and put helicoil in it, but bolt had broken a couple of times before.

3) I have checked torque specs and we are below the max torque

4) Some of the bolts have broken flush or so with the frame some down in the threaded hole and this last one broke just under the head of the bolt and just below flush in the threaded part of the hole. That's right broken in two places.

Is there anyone else out there that has had and solve this problem? Any and all ideas welcome, I have run out.:bang:

 

[jerr-06k9]

??????

 

[RCAdd1ct]

I would look for bolts with a shoulder and get rid of as much thread as you can.

 

[outdoorsman26]

I did for the first 2ys then I put stainless bolts in and haven't lost one yet

 

[jimizee028]

Is he riding home the really fat girls late at nite when the bar closes????????
Maybe get him to realize there really is a weight limit on our bikes.........

 

[RRRUFF]

I would look for bolts with a shoulder and get rid of as much thread as you can.

The BDM recall bolt kit was shouldered bolts and the same bolt breaks each time. We are going back with those this time.

I did for the first 2ys then I put stainless bolts in and haven't lost one yet

Haven't tried stainless yet, but his bolts are breaking.

Is he riding home the really fat girls late at nite when the bar closes????????
Maybe get him to realize there really is a weight limit on our bikes.........

He says he's not riding any girls that shops at the "Lots to Love" department at Sears.:lol:

 

[kirk927]

I went with the stainless from Lowes bolt rack, 11,000 miles and no breakage yet. I put a bit of antiseize on these and they have'nt loosened up. I also ride 2-up with no issues.

 

[2004BC]

Bolts have grades so make sure your using a grade 8 bolt.

 

[bruce]

I also have 2006 K9 mine were some of the first bolts to break, had replaced twice under warranty the second time was the recall, I no the washer that come with the replacement bolt have something to do will them not breaking, do you have them, they are different then regular washer. I was told from bigdog that the replacement bolt were above grade 8 but that could have been bull s--t.

 

[Moespeeds]

All cap heads are supposed to be grade 8 but you gotta get them from a reputable vendor. My guess is those threads are fucked and it's working in the hole. I would shim the strut a little so it's really tight and replace all bolts. Put a dab of orange nail polish on the bottom of the bolt where it mees the strut so you can see at a glance if it's moved. If they break again, drill and tap the frame and go up a bolt size, you should have enough meat on there. Depending on your struts you may have to ream and countersink the new holes and get them re-chromed but that should fix it once and for all.

 

[San Diego Dog]

Grade 8 bolts. They won't break.

 

[RRRUFF]

All cap heads are supposed to be grade 8 but you gotta get them from a reputable vendor. My guess is those threads are fucked and it's working in the hole. I would shim the strut a little so it's really tight and replace all bolts. Put a dab of orange nail polish on the bottom of the bolt where it mees the strut so you can see at a glance if it's moved. If they break again, drill and tap the frame and go up a bolt size, you should have enough meat on there. Depending on your struts you may have to ream and countersink the new holes and get them re-chromed but that should fix it once and for all.

The last bolts we tried were from Fastenal they said thats the strongest they have. The last time I did cut and put a shim between the strut and the frame to tighten it up. I had the same thought on the hole being messed up so I drilled and installed a heli-coil, screwed in the bolt and it was very tight. Going with a bigger bolt is something we have considered and we are saving that for our last option. It is the same bolt each time that is breaking and this last time the same bolt was broken in two places.

I also have 2006 K9 mine were some of the first bolts to break, had replaced twice under warranty the second time was the recall, I no the washer that come with the replacement bolt have something to do will them not breaking, do you have them, they are different then regular washer. I was told from bigdog that the replacement bolt were above grade 8 but that could have been bull s--t.

We have used the time before this last time the BDM recall kit with the same results. However those washers are good locking devices.

Thanks for the ideas guys, keep them coming if you think of anything else.

 

[erldawg]

I would try outdoorsman26 suggestion with stainless...and use the BDM lock washers...

Make sure Made in USA bolts....

 

[RRRUFF]

I would try outdoorsman26 suggestion with stainless...and use the BDM lock washers...

Make sure Made in USA bolts....

I am also considering the stainless bolts. My thought is that maybe a softer bolt will bend before it breaks, just in case there is some misalignment in the bolt holes.

Thanks!

 

[Moespeeds]

Stainless is more brittle than grade 8 and has less tensile strength. The grade 8 will deform far more before breaking than the stainless. I use stainless all the time for non-structural applications, like holding on an air cleaner, or holding an inspection cover. I would never use a stainless bolt to hold on a forward control, handlebars, struts, engine mount, etc etc. Do some research via google before you stick a stainless bolt in anything. They aren't good for shear applications or high vibration.

 

[RRRUFF]

Stainless is more brittle than grade 8 and has less tensile strength. The grade 8 will deform far more before breaking than the stainless. I use stainless all the time for non-structural applications, like holding on an air cleaner, or holding an inspection cover. I would never use a stainless bolt to hold on a forward control, handlebars, struts, engine mount, etc etc. Do some research via google before you stick a stainless bolt in anything. They aren't good for shear applications or high vibration.

Thanks Moe, my thoughts are to put something in there that is more ductile, that will bend before it breaks.