RG Adventure Bars Bolt Replacement Snag

[BigD]

I'm finally getting around to replacing the lower engine mounting bolt with the longer bolt supplied by R&G after the center stand bracket replacement. When driving the old bolt out from left to right, the new bolt is getting hung up just at the point the old bolt pops out on the floor.   Something is not lining up.  I can put the old bolt back in no problem.  Anyone had this challenge?  The engine may be shifting ever so slightly messing up alignment?   I'm thinking of grinding a slight taper onto the end of the bolt to possibly help ease things into position.
Thoughts?
Thanks

[Coconut]

Hi BigD,

I would guess you are right about the engine shifting slightly when the old bolt is pushed out -
it's probably dropping just enough to prevent the new shaft from lining up 

With the Fairing off can you get under the engine with a small jack
to take the weight off the engine and stop it from dropping ?

[BigD]

Originally Posted by Coconut

With the Fairing off can you get under the engine with a small jack
to take the weight off the engine and stop it from dropping ?

I don't know.  My one quick look at that left me thinking the exhaust pipe may be in the way.  The rub is I had just put all the plastic back on after running wiring for Denali lights.  Wouldn't ya know.     I suppose it only takes few minutes to pull the left side back off.   First I think I will grabbing a mate and having him wiggle the old bolt up and down as I drive it out with the new.  Perhaps that will allow it to slide into place.

BTW  -  Stay tuned for some photos of modified adventure bars.
 

[Roger]

Hi Big D

I wouldnt taper the bolt, from my experience with threads that would be a quick way of cross threading. I know its a pain taking the plastic off but yourl have the bars on the bike for years and lining the bolt up even if takes a couple of hours it'l be worth it in the long term( easy for to say I know ), can you shine a torch in the hole to see whats happening ?

Good luck

Roger

[BigD]

Originally Posted by Roger

a quick way of cross threading. I

Cross threading doesn't conmcern me too much.  I can redress the threads for a good starting point.  The possibility of that is good to keep in mind so one can go slowly starting the nut.  I can tell by feel if the nut is starting properly. As long as I keep it in mind.    Once the right nut is on it may never have to come off again.  I think having a mate fiddling with the old bolt as it comes out is my first move. Then the jack.

[Roger]

"I think having a mate fiddling" stop there ! that will not help !!!

Roger

[BigD]

Originally Posted by Roger

"I think having a mate fiddling" stop there ! that will not help !!!

Roger

Just have to choose the mate carefully.   

[trophied]

I have R&G bars that were installed before the centerstand bracket was installed and I didn't know about this issue.  What is the result of not having changed the bolt out?  Is there a possibility of catastrophic failure?  I've put over 2000 miles on it since the bracket was replaced.  I'll have to check with the dealer about this to see if they just recognized the problem and changed it on their own without mentioning it or not.  So far they have given me any details I asked for about all the work they've done on all the bikes they worked on for me.