Crash bung bolts 5mm too long

[bert_is_evil]

I fitted one of my new crash bungs to the "near" side of the ace last night, it seems the bolt is about 5mm too long and the bung can slide in and out about 5mm on the bolt - should I leave it as is or have the bolts shortened? Any suggestions as to where to go to get them trimmed up?

I couldn't get the engine bolt out of the "far" side, a bit akward jumping up and down on the allen key trying to hold the front brake on (parked on a hill) and lean my weight far enough over the bike to stop it tipping, while the suspension keeps compressing and the bike's bouncing around, and I'm trying to hold my knee up against the fairing to push it in far enough for the key not to catch the paintwork if it does move. I'm wearing a beanie and a headlamp 'cause it's dark out and people keep driving slowly by mouthing the words "are they stealing that bike?" to each other in their cars....

[Pumba]

Who did you buy them from? Cause I would be paying them a visit and asking, no telling them to supply me with the right size bolt or money back.

And no I personaly dont think you should leave it so it floats in and out by 5mm, that quite a bit of movement, and for me all it would do is ratlle and anoy the crap out of you

[MSTRS]

Yeah, shorten the bolt (or add a/nother spacer). As far as the other side goes, a (longer) lever is your friend.

[Sensei]

As far as the long bolt goes just get a hacksaw & cut it yourself after messuring the length corectly so as not to make it short ! File the end once cut so it can start into the thread straight . If the Allen keys bolt is that tight try some CRC / WD40 around bolt & leave for an 1hr then try again , may pay to take side of so you can see what is happening , bolt may have nut on the back of it . Try a Allen key socket on a Power bar if you have one .

[bert_is_evil]

I'd cut them myself but I don't have a vice unfortunately, will take the fairing off on the far side and find something to give me a bit more leverage.

I've just emailed the company (r&g racing via amc motorcycles in aus) asking them to refund the cost of me getting them altered (don't really want to wait another 4 weeks for new bolts) as this kind of thing pisses me off - I didn't pay $200 to have to faff about with them!

[bistard]

Are both the bolts for both sides the same length??
If you are having trouble with the allen key,put a ring spanner on the end of it for more leverage
Two options for the bolt,either cut it,or pack the other end with 5 mil of washers
If you need to cut it,where are you in Wgtn,send me a PM & I could cut it for you

[nudemetalz]

I'm also happy to shorten the bolt for you too if you want (if Bistard hasn't already).
I'm working on the Guzzi tomorrow morning (oil change, tappets), so feel free to drop in.

[skelstar]

Your bike doesn't want to be on the track does it Bert? :)

[bert_is_evil]

Thanks for the offer guys, I never thought of packing the other end with washers (seems obvious now...)

[bert_is_evil]

Your bike doesn't want to be on the track does it Bert? :)

I think it's seen what happened to the last one and is scared

[et al]

Re the bolts you cannot get undone: you may have already checked this out - but have you checked whether there is a pinch bolt holding the shaft of the bolt you are trying to undo? (usually the case on at least one side if you are putting the crash bungs into the engine mounts).

[bert_is_evil]

Is that where there's another bolt holding the hole closed? I didn't notice one although it was dark and I didn't really look for one, will check that out

[Gremlin]

...trying to hold the front brake on (parked on a hill)
bit far away from wellers to help... but some advice.. put the bike into gear, and it will stop it rolling. Same as parking downhill, as long as the clutch isn't engaged, it rocks against the gears, and doesn't roll.

[Mental Trousers]

I'd just put a spacer or washers in there to pack it out a bit. Nothing wrong with a crash bung sticking out another 5+mm eh.
I suggest you find some help with the other one. A swingarm stand and someone to hold the bike steady is much safer and less aggravating.

[nudemetalz]

How did you get on, Bert ?

[bert_is_evil]

The bungs are on and protecting the ace from car park incidents as we speak :yes: I put 5 additional washes on the outside end of the bolt on the near side, and the far side one turned out to be the correct length.

In the light of day I discovered there was a pinch bolt as et_al suggested (pays not to do these things in the dark with only a AAA headtorch?) so I loosened it off and with a bit of extra leverage from a peice of squashed pipe I managed to get it ondone quite quickly.

Thanks for your advice everyone!

[nudemetalz]

Lets hope you never have to test them out !!!