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Oh crap! 07 800PT clutch bolt?

Ok guys my buddy installed some Dalton adjustable pins in his primary w-out removing the back half of the primary from the crank. Torqed the bolt to 80 lbs. During the test run he was down a few hundred rpms. Tried to pull the primary but the primary bolt would only come out 1/2" & then lock up. Long & short of it the threads are now buggered up in the end of the crank! Have a new clutch bolt ($50.00 usd) but can the threads be cleaned up or is he screwed?
 
Wierd. I would try a QUALITY tap....not a cheapo that will break off or not cut the hardened crank.
Did he get the bolt out?
 
Ok guys my buddy installed some Dalton adjustable pins in his primary w-out removing the back half of the primary from the crank. Torqed the bolt to 80 lbs. During the test run he was down a few hundred rpms. Tried to pull the primary but the primary bolt would only come out 1/2" & then lock up. Long & short of it the threads are now buggered up in the end of the crank! Have a new clutch bolt ($50.00 usd) but can the threads be cleaned up or is he screwed?

It happened to me last year. I torqued it out(no choice) and tried turning in a new bolt. No go, so before I wrecked it I bought a tap and cleaned up the crank threads. No problem after that, I guess the crank is harder than the bolt. Lucky for me and your buddy.

The tap says M14 x 1.5 on it.

Good idea to put some antiseize on these I think.
 
That happened to my 04 800. I took it to the dealer and he was able to get the bolt out by cutting the inner sheave to get access the the bolt (head had snapped off). You might talk to a machinist and see if heating and cooling the bolt would soften it so you could strip the bolt and save the crank.
 
If you plan on tapping it, use lots of cutting oil and lots of patience. I had a TRA explode on my 800 triple mod at 9200 and come through my hood/bellypan/secondary/belt guard/helmet. The extra patience pays off!
 
Ok I got home from work last night & my buddy was in my shop working on the sled, He used a good tap w/lots of lube & the threads came back up very nice.
Torqued the bolt & ran the sled up 20 mph on the stand, Rechecked the bolt & got a 1/4 turn, Retorqued again & the same 1/4 turn then it was fine. We are hoping this issue was from not rechecking the bolt.
 
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