That's a tough one my friend! I've done a few of these, and they are never easy!

On the 250's:
What typically happens is the spacers sieze onto the bolt... (Spacers b/w the swingarm and the frame)The only thing i've found that works, is to use an impact wrench on the bolt (Keep hammering on it until it starts to spin) along with an air chiesel on the spacers.... It beats the he!! out of the spacers, but it usually breaks them free.. once they are free, you can usually get the bolt out without too much pain..


One the 500's:
The bolt is either siezed into the bearing cages, or the case itself.. I'd be willing to bet on the bearings. One must 'be vewwy vewwy caweful' when hammering on the bolt... first of all the bolt becomes useless (Not the end of the world.. but I paid $50 for my last one)
not to mention you can bend the daylights out of the frame... (Yes, I use a very BIG hammer)
I would really hesitate cutting it out... or at least save that as the last resort.
Since your bearings are shot anyhow... heat might be worth a try.. but I'd heat directly on the end of the bolt and not on the cases of the motor.
If you've got access to an air chiesel, using a pointed bit... you could vibrate the daylights out of the bolt to try and break it free that way.

Good luck bud!

 

I GOT IT OUT!!!!![img]i/expressions/face-icon-small-happy.gif[/img]

I had to cut the swingarm off like MOTO said with a sawzall. Then drilled the center with 3/8" drill all the way through. Still stuck in the case. I then drilled it out with a 1/2" bit the taped the POS thin walled bolt out.

No damage to the case and very very little to the swingarm[img]i/expressions/face-icon-small-shocked.gif[/img]

Thanks for all the help:cool
Mike

ps YES I WILL GREASE THE NEW ONE