bolts that won't go back in - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

LinkBack Thread Tools Display Modes
post #1 of 6 Old 03-12-2015, 06:00 PM Thread Starter
2nd Gear
Join Date: Nov 2012
Posts: 216
bolts that won't go back in

Took off the bolts on the rear hand grabs and they were either rusted or the threads are damaged because they will not screw back in.

What options do I have?

Crashoverride is offline  
Sponsored Links
post #2 of 6 Old 03-12-2015, 06:07 PM
Join Date: Jan 2011
Location: NW MO
Posts: 5,453
I utilize those eBay side panel guards that really don't do much but are a good tiedown point for stuff on the seat behind me so I keep using them.

They bolt to the rear rack/hand grab holes; the ones on the side. I've found that every time I take those racks off to access the air filter or battery, the rear rack shifts quite a bit and I have to finagle it around to get the hole/threads to line up again. It's like the front of the rack pops up and back as soon as I take those bolts out so everything's out of alignment.

Have you taken a good look to make sure the holes in the rack are aligned with the threads?

planalp is offline  
post #3 of 6 Old 03-12-2015, 06:50 PM Thread Starter
2nd Gear
Join Date: Nov 2012
Posts: 216
I have the grab rails off so it appear to just be the bolt hole in the frame. I don't think there is anything else to align with at that point.

Crashoverride is offline  
post #4 of 6 Old 03-12-2015, 07:13 PM Thread Starter
2nd Gear
Join Date: Nov 2012
Posts: 216
Ok so I got one in, turns out the other actually had snapped off inside the frame and I didn't notice it was a little shorter at first.

So now I have to figure out how to get that broken bit out.

Crashoverride is offline  
post #5 of 6 Old 03-12-2015, 08:04 PM
4th Gear
GoMotor's Avatar
Join Date: May 2014
Location: Texas
Posts: 1,260
On my gen2 KLR those holes are open on the back side. In that case I would consider soaking the bolt in penetrating oil and drilling a small pilot hole a short way into the center of the broken bolt. Then I drill through with a larger bit, but one small enough not to damage the threads. The oil and the heat from drilling could cause the bolt to catch on the bit and go out the back. If not, I would use an easy out extractor in the drilled hole.
GoMotor is offline  
post #6 of 6 Old 03-13-2015, 11:21 AM
4th Gear
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
Part of the problem with alignment may be that the structures shift under the stress of riding. It is best practice to loosen off all bolts retaining a component, then start all the bolts several threads before tightening any. What often happens is that someone will tighten each bolt as it is inserted which results in misalignment of holes such that subsequent bolts will not fit. Another common result is that the uneven strain breaks or distorts the component being attached. If you're anywhere near Chilliwack, I'll be glad to help.
Normk is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
Bolts And Hoses kevinm219 1987 to 2007 Wrenching & Mods 9 07-18-2013 09:54 PM
Check your bolts! ArcticKLR 2008+ KLR650 Wrenching & Mod Questions 6 11-19-2012 07:06 PM
Replace your bolts! whiskey hound 1987 to 2007 Wrenching & Mods 22 08-15-2012 05:15 PM
Bolts and Nuts Tux3do KLR & Other Motorcycle Related Discussion 0 06-22-2009 08:14 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome