Stripped heat shield bolts - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

  • 2 Post By DPelletier
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post #1 of 4 Old 08-11-2016, 02:42 PM Thread Starter
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Stripped heat shield bolts

So I thought it would be a great idea to replace heat shield screws with stainless.
I noticed they got a little tight so I tried to back them out and stripped both of them. Now what?
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post #2 of 4 Old 08-11-2016, 02:53 PM
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Don't recall but I doubt there is a lot of material there for threading or an insert. Might have to go without them now. I did that long ago and replaced with stainless bolts and used a high heat thread lube on them. I had less success removing the muffler plugs. Sheared them both off. Why they can't lube those threads assembly is beyond me.

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post #3 of 4 Old 08-11-2016, 03:16 PM
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For those that can get them out, Never Seez works well. Unfortunately breaking those bolts is a very common occurance. Once broken, it's drill, EZ out, tap, etc. Stripping the heads isn't a whole bunch better; you can try to cut a notch, weld on a rod or whatever but odds are the bolt will break anyway.

.....or you can do what I did and just replace the Gen1 header pipe with the nicer, tubular SS Gen2 one which happens to come with a nicer guard.

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post #4 of 4 Old 08-12-2016, 02:07 PM
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Stainless hose clamp?
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