and I (and another friend) were helping a fourth friend get his 1000DS back together this afternoon and the craziest thing happened...
Background first: For lack of a better description, the fancy DS swingarm has a pivot compression/tensioner bolt rather than a pinch bolt. The tensioner bolt has a wedge shape cut into it so as you draw it tight, it presses the pivot against the interior of the swingarm pivot passage, completely unlike the other SS swingers that use a traditional pinch bolt and tend to crack.
So the bike owner is manning the torque wrench, turning gently waiting for the nut to snug up to 37 NM and it never does. It never torqued, instead the nut continued past the end of the threads on the tensioner bolt and the wrench never clicked.
and I both watched this process and started getting curious after it was obvious the nut should have seated. It didn't. We tested the wrench on another bolt and it operated as expected, so it wasn't a tool failure.
At this point we stopped. We tried backing the nut off the tensioner, but we couldn't get it to bite back onto the threads. It's one of those deformed single use nuts. We tried all sorts of things to get it to thread back on, but gave up after about 2 hours of trying.
That's when we resorted to the power tools. You can't imagine what happened next. Lets just say the nut is no longer on the tensioner, and the tensioner has a tidy 3/16th hole drilled through completely through the middle of it, and the tensioner still won't let go of the pivot, and believe me, we tried tapping it out from all angles with all forms of punches, chisels and hammers.
Also, I apologise in advance for my first pass at trying to write this out. I went home and started working on some healthy margaritas after 5 hours of trying to get this bolt to go away.
Here's to hoping someone has come across a tensioner that dropped straight into the swingarm but won't let go under any influence. We can't seem to figure the physics out on this one, and there were four pretty smart people watching this happen.