Back rack breaking bolts. - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

LinkBack Thread Tools Display Modes
post #1 of 2 Old 05-09-2015, 07:47 PM Thread Starter
Join Date: Apr 2015
Posts: 4
Back rack breaking bolts.

I put a military surplus box on my back rack and bolted it to my rack via the 4 bolts that go to the passenger hand grips. First test ride the fender bolts "the two that go through the rack and middle of fender" rattled loose. Put locktite on them and they broke. Was thinking of drilling the box and putting longer bolts through the box and some rubber in between to help with vibration. Thanks for any help or ideas.
toddbiss is offline  
Sponsored Links
post #2 of 2 Old 05-09-2015, 08:40 PM
4th Gear
GoMotor's Avatar
Join Date: May 2014
Location: Texas
Posts: 1,248
I use large 30"x12"x12" aluminum tool boxes as tail boxes on both my gen2 KLRs. I put quite a load in the box and ride long distance dirt road routes with lots of bumps. I broke three sets of the stock 6mm vertical bolts holding the rack down.

The solution is to replace the 6mm with 8mm with 78% more cross sectional area. On one gen2 I drilled and tapped the nuts to 8mm. On the other I just knocked the captive nuts out of the "U" bracket that holds them and put in an 8mm nut with a lubricated bolt through it to hold it in place. Then I packed the "U" bracket with JB Weld to hold the nut in place. When the JB cured I unscrewed the lubricated bolt. This left the nut firmly and perfectly in place with room for a bolt to screw a little past the nut in the bracket. The bolts are 35mm long, but all I could find at the hardware store were 40mm. So I cut of 5mm with my Dremel and all is good.

I think the drill and tap method is better, but both worked for me.
GoMotor 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
rear rack bolts Crashoverride 1987 to 2007 Wrenching & Mods 12 08-19-2017 04:43 AM
bolts that won't go back in Crashoverride 1987 to 2007 Wrenching & Mods 5 03-13-2015 11:21 AM
Breaking In The New Bike ridgerunner 2008+ KLR650 Wrenching & Mod Questions 9 01-25-2010 07:53 PM
breaking in the motor on my new '08 ep!c Travel Log & Trip Reports 0 05-06-2008 11:51 PM
What size are the bolts on the rear rack? Timbo 1987 to 2007 Wrenching & Mods 2 07-14-2007 08:19 AM

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