Bolt specs for '04? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 7 Old 04-01-2011, 06:48 PM Thread Starter
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Question Bolt specs for '04?

I have shaken a few bolts loose and they are gone. I am doing my spring maintenance and want to buy some replacement bolts. I can't find the specs online anywhere....anyone know where I can find the bolt specs?

thx in advance,
Lizard
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post #2 of 7 Old 04-01-2011, 06:53 PM
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It must be out there somewhere, but if you tell us which ones went AWOL we'll help you figure it out.

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post #3 of 7 Old 04-01-2011, 07:58 PM Thread Starter
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OK, I am going from memory here....my moto is in pieces in my girlfriends driveway (and yes, she IS fine with it there!). There may be more but here is what I can recall.

I was looking at some KLR OEM parts diagrams at bikebandit.com and copied down their codes for the missing bolts. I am not sure if they are Kawasaki codes or bikebandit codes for the bolts (in brackets).

1) bolt that attaches windshield to cowling (92009)
2) bolt that attaches side cover to frame (92172)
3) bolt that attaches engine shroud (fairing?) (92009A)
4) bolt that attaches muffler to frame or subframe (92153)

I am hoping to source the bolts locally instead of paying $$$ from a parts supplier!

Doing the doo, subframe bolt upgrades, lubing suspension and painting muffler. Should be like new for the upcoming riding season!

thanks in advance,
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post #4 of 7 Old 04-01-2011, 09:14 PM
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Above are the standard dimensions for metric bolt fasteners, and the grades available. Below are the bolt heads I prefer to upgrade to, in stainless steel.




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post #5 of 7 Old 04-01-2011, 09:36 PM
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Quote:
Originally Posted by Lizardrider View Post
OK, I am going from memory here....my moto is in pieces in my girlfriends driveway (and yes, she IS fine with it there!). There may be more but here is what I can recall.

I was looking at some KLR OEM parts diagrams at bikebandit.com and copied down their codes for the missing bolts. I am not sure if they are Kawasaki codes or bikebandit codes for the bolts (in brackets).

1) bolt that attaches windshield to cowling (92009) 5x12 screw, 5mm self threading plastic nut

2) bolt that attaches side cover to frame (92172) 6x10 screw

3) bolt that attaches engine shroud (fairing?) (92009A) SCREW,5X14

4) bolt that attaches muffler to frame or subframe (92153) BOLT,8X16

I am hoping to source the bolts locally instead of paying $$$ from a parts supplier!

Doing the doo, subframe bolt upgrades, lubing suspension and painting muffler. Should be like new for the upcoming riding season!

thanks in advance,
Not sure what you may have available for hardware stores, and if memory serves me correctly, most things in your neighborhood are connected with Caribou sinew or rabbit tendons aren't they? If it comes down to it, I guess you could always get them brought up on the dog sled from Kalispel.

******
“many a trip continues long after movement in time and space have ceased”- Steinbeck, [I]"Travels with Charlie"
[/I]
[IMG]http://i718.photobucket.com/albums/ww187/vatrader01/KLR%20mechanical/04e28c5e.jpg[/IMG]

[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]

Last edited by vatrader; 04-01-2011 at 09:44 PM.
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post #6 of 7 Old 04-01-2011, 10:47 PM Thread Starter
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thanks Vatrader,
yes my KLR is currently held together with sinew and tendons....but it is ELK sinew and DEER tendons! I am going to replace these trusty organic tethers with something more 'industrial'. Something trusty from the tool crib at my local machine shop!

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post #7 of 7 Old 04-01-2011, 11:16 PM
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The two upper subframe bolts (search for Subframe Bolt Replacement) are usually replaced but they work very well to replace the rear muffler bolt (lost returning from San Diego) and the rear tail pipe bolt (lost going to San Diego). They are still on my KLR.

There is also a bolt behind the rear master cyclinder that attaches the tail pipe to the muffler. This bolt will vibrate loose usually because most new KLR riders don't know it is there. If it is there, remove it, clean it, Loctite, torque, and reinstall. It should be good after that.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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