Back rack breaking bolts. - Kawasaki KLR 650 Forum
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post #1 of 2 Old 05-09-2015, 07:47 PM Thread Starter
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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.
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post #2 of 2 Old 05-09-2015, 08:40 PM
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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.
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