broken adjustment bolt

[TrapZ400]

Yesterday I rode all day and at the end a started to hear a rattling sound coming from the sprockets. So I went back to my house to wash it and figure out what was wrong with it. I looked at the back of it and saw that the adjustment bolt was hanging off. I took off the plate on the back and I noticed that the bolt was broken. What should I do?

[jonboy]

Is it an 03 with 2 bolts or an 04 or newer with one. The 03 that I've been working on(see project Z in this forum) had one of the bolts broken. I welded a nut to it, turned it out and replaced it with a new one. Honestly, I believe I got lucky but, if you have enough of the bolt left on the carrier its worth a shot.

[YFZ450Ridr]

both broke on my 03 and my dads 04 single bolt broke also. on my 03 the bolts had to be drilled out and retapped, on my dads the bolt was taken out with vice grips and we just ordered a new one. a few options lay on the table.

[TrapZ400]

Originally posted by jonboy
Is it an 03 with 2 bolts or an 04 or newer with one. The 03 that I've been working on(see project Z in this forum) had one of the bolts broken. I welded a nut to it, turned it out and replaced it with a new one. Honestly, I believe I got lucky but, if you have enough of the bolt left on the carrier its worth a shot.
Its an 05. I cant weld a nut on it because it isnt sticking out at all.

[jonboy]

Man that sucks. More than likely you'll have to do like YFZ450Ridr did. You'll probably have to use an easy-out to remove it. If you do it yourself be sure to take your time to do it right. You dont want to destroy your carrier. :ermm:

[05Z400rdr]

Wow...and i thought I was the only one having this problem...

Yeah actually I am on my 3rd adjustment bolt.
My first one broke and I was able to back it out with an easy-out.
About 20 minutes ago, I just was working on my carrier because the bolt broke again. This time, an easy out would not take it out...it was so hard that using the easy out snapped our wrench in half and the flying wrench flew threw the air and shattered the glass in our garage door<a href="http://plugin.smileycentral.com/http%253A%252F%252Fwww.smileycentral.com%252F%253F partner%253DZSzeb008%255FZNxmk572YYUS%2526i%253D36 %252F36%255F11%255F6%2526feat%253Dprof/page.html" target="_blank"><img src="http://smileys.smileycentral.com/cat/36/36_11_6.gif" alt="SmileyCentral.com" border="0"><img border="0" src="http://plugin.smileycentral.com/http%253A%252F%252Fimgfarm%252Ecom%252Fimages%252F nocache%252Ftr%252Ffw%252Fsmiley%252Fsocial%252Egi f%253Fi%253D36%252F36_11_6/image.gif"></a>. Therefore, we drilled it out with a 13/32 drill bit and got a 12 x 1.25 tap (same size as stock) and tapped it out. It works, but I am not sure of how long it will hold up... I deffinately plan on having this problem again... it happened to me 2 times in about 4 weeks. hope i was of some help,

Landon

[TrapZ400]

Where can I get one of those easy out tools?

[05Z400rdr]

my dad picked one up at a place called Capital nut and bolt. so pretty much any place that specializes in bolts and nuts and stuff should carry them

[05Z400rdr]

TrapZ400
So howd you make out??
Landon

[KILLSWITCHngage]

The Z has the most crapped up swinger design on a quad. The 4 housing bolts are gonna give if you hit something hard enought and when that housing twists just a little, it weakens or breaks that godforsaken adjustment bolt. mine has broke 4 times, time for a HOUSER swingarm

[TrapZ400]

Originally posted by 05Z400rdr
TrapZ400
So howd you make out??
Landon
I got it out. Now I have to buy the bolt. I called three suzuki dealers and neither of them had it in stock. Now I have to wait for them to get the bolt for me.

Thanks for the help guys!

[Villageidiott23]

i have an 06 and have never experienced this problem. i hear the complaints about the swinger being a crappy design but what do i have to do to break mine. i ride the piss outta my bike jumping rolling and stuff like that and ive never broken it. are any of these problems caused by faulty maintenance by the rider or what.... ive only adjusted my chain on my bike one time and every ride i check it and its fine. what the hell.

[05Z400rdr]

Originally posted by Villageidiott23
i have an 06 and have never experienced this problem. i hear the complaints about the swinger being a crappy design but what do i have to do to break mine. i ride the piss outta my bike jumping rolling and stuff like that and ive never broken it. are any of these problems caused by faulty maintenance by the rider or what.... ive only adjusted my chain on my bike one time and every ride i check it and its fine. what the hell.

Yeah...I have an 05 (obviously..lol) mine broke 2 times so far. I know that inside the swingarm, where the carrier sits, it is warn down a little bit. Most likely the reason mine broke a second time is because i didnt tighten the hell outta the 4 bolts on top (which you need to do) and 2 of them were actually loose that i could twist them with my finger. make sure you tighten them very VERY hard...just like they were from factory. the rearend on the Z's is totally a messed up design..

[TrapZ400]

I got the bolt and I dont know how to put it back on?

[05Z400rdr]

Originally posted by TrapZ400
I got the bolt and I dont know how to put it back on?

well we took a the nut that was on it, and another nut the same size and put them back to back and turned it in. i forget where i got the other nut tho...? let me kno how u make out..

Landon

[TrapZ400]

I took the nut that was on it and I put another one on it. And I turned it to the right and it doesnt seem like it is going in. Am I doing it right?

[05Z400rdr]

Originally posted by TrapZ400
I took the nut that was on it and I put another one on it. And I turned it to the right and it doesnt seem like it is going in. Am I doing it right?

yeah..your doing it right. just make sure that the threads arent too messed up from when the other one broke. also, if you looked at th bolt before you started putting it in, there is like a darker green/hunter green color on it...im pretty sure that that is some type of thread locker so it doesn't back out easy..and therefore it will be harder to put in.

[TrapZ400]

How much of the bolt should be sticking out?

[05Z400rdr]

Originally posted by TrapZ400
How much of the bolt should be sticking out?

turn it in until it stops (the whole way)

[TrapZ400]

05Z400rdr can you give me step by step intructions on how you put the bolt back in. I think Im not doing something right. Thanks

[05Z400rdr]

TrapZ400


1. take the new adjustment bolt.

2. start the threads in with the side of the bolt that has the least amount of threads and it has a dark, hunter-green color on it.

3. take two nuts that both fit the bolt and put them back-to-back.

4. use ratchet to twist it in. (remember: lefty loosey, righty tightey)

5. keep turning the bolt in until the bolt stops and will not go any further (the whole way).

6. then back the nuts off and reassemble your rearend.



hope that was some help:(

tell me how you make out..and if they helped out or not

Landon

[TrapZ400]

ok i used the 2 nuts and i tightened them. then i toke off the two nuts. but now there is a half an inch of bolt sticking out.

[05Z400rdr]

OH!! ok i'm sry...i told you wrong. don't turn the bolt in until it stops. turn it in until you reach the end of the short-threaded area. if you look, between the short-threaded area and the long-threaded area, there is a small area that has no threads on it. you want that to be showing...and outside of the carrier.i'm so sorry, only turn it in until u see no more threads on the short-threaded side.

tell me if you get it and make out

thanks,
Landon

oh yeah...when you do assemble it, dont have your chain too tight, that puts tension on that bolt and is what usually breaks it.

[TrapZ400]

ok so the way i have it now is the way it is supposed to be?

[05Z400rdr]

i'm not quite sure what you mean..? there should deffinately be more than 1/2'' sticking out. I have an extra bolt and i am looking at it right now and there should be almost exactly 2'' sticking out. i don't know how you would have got it in that far..? could you please put a picture on so i can see what you are talking about? thanks

[TrapZ400]

there is a half an inch of the bolt that is sticking out of the adjuster nut

[TrapZ400]

when i turn the bolt to the left to move the axle back toward the rear shock to put the chain on the snap ring on the other side of the plate falls off

[05Z400rdr]

Maybe this will help you...? I just took this pic and labeled it for you...

[TrapZ400]

yeah i know
I have the the plate and the adjuster nut on and there is like a half and inch of bolt sticking out

[05Z400rdr]

I'm still confused...so you do have the nut on the bolt? if so, how thick is it? add that to the 1/2'' you have and see if that gives you 2''. is it possible to send a pic or 2 or sumthin?? where is there a 1/2'' of the bolt sticking out?...out the back with the nut already on?

[05Z400rdr]

You have to have all 4 carrier bolts loose before trying to push the carrier forward. The reason that the snap ring is falling off is because you don't have the 4 carrier bolts loose or loose enough. do you get what i mean?

[TrapZ400]

I figured it out. i dont know how I did it but i did it. lol
Now all i have to do is put the back end together.
Thanks for your help i really appreciate it.

[05Z400rdr]

lol ok thats good. anytime bud!...if you have aim, you can IM me at YoLando92 whenever I'm on. ok ttyl.

Landon