Today’s 4×4 utility ATVs are build to withstand various terrains, but riding extremely rough terrains over time will start to take its toll on the mechanical assemblies of your ATV. I am talking about the nuts and bolts that hold things together.

Often overlooked, the nuts and bolts on your ATV need to be inspected and checked for proper tightness or torque. Many manufacturers will use special locking nuts, thread sealers and cotter pins to keep critical assemblies from coming apart such as the steering components.

Having to inspect and check every nut and bolt with a wrench takes time but is a necessary task. There is a way to get a quick visual of your critical hardware to ensure things are tight and safe. That is by the use of safety wire on vital fasteners and components.

Safety Wire ImageSafety wire is used extensively in the aircraft and racing industries to keep nuts and bolts from unintentionally loosening due to vibration. It also allows quick visual inspections of nuts and bolts to ensure that they are tight. Safety wire comes in many sizes but the most common size is .032” diameter stainless steel wire.

A bolt that is properly safety wired doesn’t just hold the bolt in place, it serves to pull it tighter. The wire should always be installed so that tension is in the tightening direction. Learning to properly safety wire nuts and bolts does take a little practice but is easy to accomplish.

Most nuts and bolts need to have a hole drilled in the head for the safety wire to pass through. The use of a jig makes this very easy. Safety Wire Kit ImageAt CampingATV.com we have a Safety Wire Kit that comes with everything you need to start safety wiring the nuts and bolts on your ATV.

Simple Safety-Wiring Procedure:

  1. Verify the fasteners have been correctly torqued and that the holes are properly aligned with each other. NOTE: Never over torque or under torque fasteners to obtain proper alignment.
  2. Measure the distance between the fasteners being safety wired. The wire should be twice the distance measured plus another 20 – 30%.
  3. Install safety wire half-way through the hole of the first fastener with the wire wrapped around the head of the nut, bolt, or screw and twisted so that the loop of the wire fits closely to the contour of the fastener being safety wired.
  4. Grip both ends of the wire and pull tightly towards the next fastener to be safety wired.
  5. Using the safety wire pliers, grip both ends of the wire in the jaws at the distance of the next fastener and lock the handles. Keeping the wire taut, pull the knob on the pliers and the pliers will start spinning twisting the wire.
  6. Generally 7 – 10 twists per inch is acceptable. Excessive twisting will over-stress the wire. Unlock the handle and release the wire.
  7. Safety Wire ImageThread one end of the wire through the hole in the next fastener then pair it up with the other end of the wire.
  8. Grip the wire ends in the jaws of the pliers about an inch away from the fastener, lock the handle and twist the wire by pulling the knob. Again 7 – 10 twists per inch is acceptable.
  9. Unlock the handle and release the wire. Using the wire cutter on the pliers cut off the excess wire leaving at least 4 – 6 twists after the loop around the fastener.
  10. Bend the ends under and inward toward the fastener to avoid sharp protruding ends that can present a safety hazard.

Having an assembly come loose on you while riding can cause lose of control and even an accident (been there – done that). Don’t risk having loose nuts and bolts, check them often and safety wire critical assemblies. If you are going to ride hard and fast you need a properly maintained ATV.

Related posts:

  1. ATV Tools
  2. Survival Kit – For You And The ATV