Stripped footpeg bolt - 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 15 Old 03-26-2008, 03:37 PM Thread Starter
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Stripped footpeg bolt

My klr650 has two bolts on each footpeg. On one foottpeg, one of the bolts tightens up only somewhat and then spins (stripped threads). what's the best way to fix this? i don't want a broken ankle when it falls off. machine shop, helicoil? I want something as strong as original please.

Thanks a lot.

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post #2 of 15 Old 03-26-2008, 04:13 PM
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drill and tap to next larger size....

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 15 Old 03-26-2008, 06:57 PM
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First determine if it's the threads in the hole or the bolt itself (very unlikely it's the bolt). If you are lucky and it's just the bolt then a new bolt is all you need but it would be best to run a tap first.

Otherwise, what DXKLR says.
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post #4 of 15 Old 03-26-2008, 07:56 PM
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It is a possibility of being a bolt. Those stock bolts are weak. I recommend upgrading to a grade 10.9 bolt which has a shoulder on the head. Replace all four bolts.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 15 Old 03-27-2008, 06:10 AM Thread Starter
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i have replaced the bolt so I guess I need to tap it out to the next higher size. The current bolt is an 8mm, so what size should I go to ? 9 ?

thanks
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post #6 of 15 Old 03-27-2008, 08:01 AM
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Just hit it with the welder...lol

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post #7 of 15 Old 03-27-2008, 08:09 AM
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Get a larger metric bolt that is easy to get if you need to replace it and not some special order bolt. Why add another headache?
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post #8 of 15 Old 03-27-2008, 11:54 AM
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What Paulo said. And I'd get a spare one to stash on the bike. Particularly if you're doing longer trips.
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post #9 of 15 Old 04-12-2008, 02:04 PM Thread Starter
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is there any spec for the "hardness" / "strength" of footpeg bolt or can I use any bolt? it seems there is a ton of pressure on these bolts especially with me jumping this hog and landing standing up on them. (small jumps)
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post #10 of 15 Old 04-12-2008, 02:32 PM
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Thought this might help you some.

What if I break/strip out my footpeg bolts?
Some of the more aggressive riders have managed to break or pull out their footpeg bolts. The simplest solution seems to be to convert the footpegs to M10 bolts; drill out the footpeg bracket, and drill and tap the mount. (The tap drill for M10x1.5 is 8.4mm or Q.)

I used the 10.0 hardness as that bolt has a nice shoulder on it. The one above that is a 12.9 and you have to use an allen wrench on those normally.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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