I'd have to check manuals, too, but I believe it was in the KLR600 manual where it was called a replacement item. The funny thing about that is that the torque requirement (which has varied quite a bit) was lower in that usage. edit: For those not familiar with the early KHI manual system, the KLR600 was the base manual so any requirements in it, unless superseded in a later supplement, carried through to 2007. Thus the bolt replacement may have carried through to 2007; dunno if it was ever superseded in a Gen1 supplement.
This is one of those things were, when asked what is needed, I suggest a replacement bolt because it's never a bad idea to replace the bolt, it isn't that expensive in the grand scheme of things, and I don't want to take any liability or have a guilty conscience should something go wrong with the bolt replacement. If a replacement bolt is used supplied the original bolt gets cleaned with acetone and used for the initial torquing, then the new bolt is installed.
Working on my own stuff I don't replace the bolt.
Do you replace your lug nuts at every tire rotation?
I thought $15 was pretty outrageous for a bolt. That’s almost a full tank of gas. Those are BMW prices for crying out loud!
For me, it’s not the money, I can certainly afford it, it is the principle. I simply don’t like wasting anything so the idea of replacing a part that does not need to be replaced rubs me the wrong way. And I see no reason at all to replace this fastener unless Kawasaki explicitly states to replace it.
BMW has a few fasteners on my LT that are one-time use, but it is pretty clear why. One is the large nut that holds the flywheel on. It is a nut that has a slot cut sideways through about half of its diameter and it is a torque and then angle turn nut that actually deforms that cut slot when tightened. It is pretty obvious that it is one-time use.
The others are the bolts that hold the clutch assembly to the flywheel, and again they are fairly small bolts with star washers and I think the main issue there was deformation of the star washers more-so than the bolts, but of course they sell the bolts and washers as a pair. I replaced mine per the BMW manual, but then had to remove the clutch when someone on the LT forum noticed in one of my pictures that one of the rivets in my clutch disk was deformed. So, I had to disassemble the clutch and send the disk back to the vendor. Don’t tell BMW, but I did not buy another set of clutch bolts.
After 20,000 miles, I am not too worried about them failing. The torque value used is well within the elastic range for bolts of that size so I am pretty sure the main issue was re-use of the star washers, but I took the risk.