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September 30th, 2018, 06:15 AM   #1
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Shifter Drum Bolt whats your opinions?

So After rebuilding my bike i was having issues with the gears.
Turns out the old shifter drum bolt which holds the drum to the star piece wasn't tight due to old loctite stopping it pulling in all the way.
Saturday i went 38.8miles to FOWLERS of Bristol my local KTM dealer hoping to rebuild over the weekend, purchased the new bolt got home and realise it was different..... see photos
The allen key head was twice as thick and so made the bolt sit proud of the shifter mechanism rather than flush like the old original one, also the new one was fully threaded whereas the original one had a smooth shaft for half the length, where the shifter star piece sits. So Sunday I decided to go back up to KTM in Bristol and took the old one with me to show them.
I got there and showed the assistant who said the part number was correct that's what KTM have supplied to which i said it sticks out and showed him the pictures on my phone. I said can you look to see if you have one he said he couldn't as that's what KTM have supplied, basically he no knowledge of bikes not very helpful at all, probally why hes behind a computer not tools.
So has anyone fitted this new bolt with the bigger head and fully threaded and had any issues with clearance? see photos you can see it clearly sticks out lol,
look forward to hearing your replys.
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Shifter Drum Bolt whats your opinions?-dsc_0177.jpg   Shifter Drum Bolt whats your opinions?-dsc_0175.jpg   Shifter Drum Bolt whats your opinions?-dsc_0176.jpg  
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October 1st, 2018, 04:36 PM   #2
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whats wrong with the old bolt ? clean up the threads and degrease the drum as well, then use red loctite if you are worried
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October 2nd, 2018, 12:23 AM   #3
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That loctite is on there is not coming off! also I think it's slightly bent where I'd put it back together and was trying to get it in gears lol
Managed to get one from a fasteners in my local town and just shaved the head off a bit job done.
Was just wondering if anyone else had the same issue or used a larger headed bolt
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October 3rd, 2018, 05:00 AM   #4
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Does the longer head actually cause an issue? I believe there's nothing close to the end of the shift drum, but it's been a while, and I may be remembering some other engine...

If there's lots of loctite on the original bolt, why not whizz a die-nut down it? Or heat it up a little which'll destroy the loctite and it'll just flake off. Is the hole also filled with loctite? Quite likely. Run a tap into the threads to be sure. Buying a new bolt seems a bit of a waste of time and money when you've got to trapse 38.8 miles each way.

Cheers... Paul
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October 5th, 2018, 03:54 AM   #5
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Yeah I know but I was going out for the day anyway up there, and where'd id tried to put it back together and it didn't pull tight it's slightly bent too.

I don't have a dye but I did run a steel bolt through the shifting drum to clean the threads out.
In the end I got one from my local fasteners shop and chopped the head down. Still in talks with fowlers to find out if they have the wrong bolts in their packets. Will Keep you updated as I'm pretty sure they have. Surely the new bolt should have the smooth shaft bit on where it sits through the shift drum coupler (the star bit) I do lots of work on agricultural machinery and am pretty sure it should in my opinion.
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October 5th, 2018, 07:38 PM   #6
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The bolt you removed is part number 0012060303 (Screw DIN6912 M6X30 8.8 )

The bolt you purchased is part number 0912060083 (Screw DIN0912 M6X30) by the look of the picture you were supplied the correct bolt for part number 0912060083.

The problem most likely stems from around 2012-2013 when in this application bolt part number 0012060303 was superseded by bolt part number 0912060083 at the same time the bolt was superseded the following parts were also superseded;

54834005044 "Shift shaft complete" this was superseded by 54834005144

54634008044 "Sliding plate" this was superseded by 61234008044

0625618052 "Ball bearing" this was superseded by 0625618050

54834015000 "Shift drum LOC. CPL." this was superseded by 54834015033

So it looks like you have the earlier parts fitted.
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