In another thread, (Fender Bolt
), I made a comment about the fact that a number of the fastenings on my 2007 DL-650 are slowly being replaced. The stainless steel allen bolts that hold the fairing on to the bike are a soft metal and often the heads strip out. There are other steel, phillips head bolts that seem to easily strip and eventually need replacing.
Recently, I had my swingarm off of my bike to do some bearing maintenance and some other work. Trying to remove the two OEM, phillips head screws from the chain guard proved to be a nearly impossible task. One bolt, I resulted to cutting a "slot" in the head with my Dremel tool, so that I could use a bladed screwdriver to remove the bolt. Its sister bolt I just plain grabbed on to it with a pair of vise-grips and twisted it out of its hole. Both screws had to have been driven into place with an impact wrench at the factory. They were impossible for me to budge without using brute force!
Here are the two "buggered" up OEM, chainguard bolts after removal.
I took them with me to Lowe's and found an appropriate length, metric, hex head bolt, along with a nylon spacer.
Left to Right: OEM bolt, metric hex head bolt, washers, nylon spacers.
In the photograph above, the white, nylon spacer on the left is as I bought it from Lowe's. The one on the right is one of the spacers that had been modified by me; drilled out to the diameter of the new bolt and sanded down to a height to mimic the "shoulder" portion of the OEM bolt.
Here is the modified, nylon spacer inserted into the chain guard.
Here is the chain guard installed with the replacement bolts.