Repairing stripped out a foot peg - Kawasaki KLR 650 Forum
How To's & Tech Guides Post your mod how to's and tech guides here. Topics will be locked only to allow editing by original author.

 2Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 17 Old 02-01-2012, 02:19 AM Thread Starter
4th Gear
 
Buildit's Avatar
 
Join Date: Oct 2006
Location: London, Ohio
Posts: 1,123
Thumbs up Repairing stripped out a foot peg

After high siding I found my foot peg had come off and it wasn't because I hadn't tightened the bolts. Upon further inspection I found the threads had stripped out from rust and corrosion. My answer was two fold....

*** KLR650, Tweeting long before your kids thought it was cool.

ADVFilmer videos of trails, reviews and other dual sport related stuff. http://www.youtube.com/user/advfilmer

Last edited by Tom Schmitz; 03-15-2012 at 04:44 PM.
Buildit is offline  
Sponsored Links
Advertisement
 
post #2 of 17 Old 03-25-2013, 12:04 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,017
Buildit,
Sorry, but I have to suggest that the FOOT REST bracket NOT BE WELDED, at least not that completely.
Maybe a of couple tack welds, only.

My reasoning, If you ever have to replace the shift shaft seal, the lower chain slipper, or heaven forbid, remove the engine. You have got a lot of grinding to do in a very confined area.
pdwestman
pdwestman is online now  
post #3 of 17 Old 03-25-2013, 12:18 PM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
There may be some truth in that above post....lol.

Best way to fix the issue is to cut out the plate and weld in a thicker one with the enxt size up bolts and use stronger bolts and good old blue!

But to each their own. It's not a simple fix but if you have the skills not difficult either.

Willys
willys is offline  
 
post #4 of 17 Old 01-28-2020, 10:52 AM
2nd Gear
 
GreatWhiteNorth's Avatar
 
Join Date: Feb 2017
Location: Winnipeg, MB
Posts: 188
This is an old post! I have a Gen 1 KLR that I bought used, discovered that the footpeg bolts had been stripped, and are drilled/tapped out to 10mm X 1.5 - I know those threads aren't in good shape, and there are only 3 threads there to hold! Stock bolts are of course 8mm X 1.25, and I have a Helicoil set, am tempted to do a Helicoil repair. I scrapped a Gen 2 frame from a parts bike I bought (had been in an accident), cut the footpeg brackets off in the hope I could weld them on/use 'em for a repair if needed. I cut the tube portion out with a Dremel cut-off wheel, revealing the back side. The square nut that's tack welded in there is thin, and not very large diameter - literally only 4 threads doing the work:



There's just not a lot of meat there for drilling/tapping out to 10mm:



I notice the Helicoil tap is slightly larger diameter than 10mm diameter, so I might be able to Helicoil it. I'd be much more confident about doing that if it had been tapped out to 10mm X 1.25 (same thread pitch). Thoughts?

Last edited by GreatWhiteNorth; 01-31-2020 at 09:49 AM. Reason: corrected thread spacing
GreatWhiteNorth is offline  
post #5 of 17 Old 01-28-2020, 12:19 PM
1st Gear
 
KLR Kool-Aid!'s Avatar
 
Join Date: Feb 2017
Location: Denver, Colorado
Posts: 88
Hi -

I had the same issue - stripped foot peg bolts - and I did the fix that Superdoo recommended (https://www.souperdoo.com/stuff%20th...ot-peg-boxes); essentially, drilling out the old nuts, replacing them with burly 10 mm nuts & bolts from the local hardware store, welding them in and grinding it flush. I'm really happy with the way it turned out and it's a permanent fix.

Good luck!
JTCrow likes this.
KLR Kool-Aid! is offline  
post #6 of 17 Old 01-28-2020, 12:32 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,017
Yes, I have what I believe is a better IDEA!

Takes four 10mm Flanged nuts turned upside down, welded into Counter-Sunk pockets of the footpeg box.

Use a 7/8 or 15/16 to drill the countersinks, which will basically release the remains of the square nuts from inside the box and remove them with long nose plier.
Drill the counter-sinks deep enough for nut to be level.

The US Navy trained welder that I hired used TIG welder. Barely had to use a grinder for level surface. He said they did thread repairs that way quite often, so it was not a new idea to him.

If you do this type of thread repair, Tom Schmitz would love to include pics in his Souperdoo description of it.
https://www.souperdoo.com/stuff%20th...foot-peg-boxes.

ps, Looks like Kool-Aid beat me to it. I type slow & got interrupted.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting

Last edited by pdwestman; 01-28-2020 at 12:47 PM. Reason: ps added
pdwestman is online now  
post #7 of 17 Old 01-28-2020, 03:44 PM
2nd Gear
 
GreatWhiteNorth's Avatar
 
Join Date: Feb 2017
Location: Winnipeg, MB
Posts: 188
Here's the thing... I can't weld (know a very good welder tho), but I'm pretty good at drilling, tapping and installing Helicoils... and I've already got the kit. Not that I think the weld-in-the-nut approach is a bad idea! I've seen some folks cut the box off, and weld nuts in from the inside... seems like a lot of work. If I Helicoil it, I'll throw up a few pics. If that doesn't turn out OK, I can try the weld in the nut method.
GreatWhiteNorth is offline  
post #8 of 17 Old 01-28-2020, 06:14 PM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,017
GWN, Don't Heli-coil it!

Just tap them to 10mm, but you need to drill the old nuts slightly, so the tap does 'push-off' a spot weld on the old nuts. That is what had happened to the one I had to have repaired on a customer bike.

You will have 10mm threads thru both the outer flange of the box & the old nuts, so more total threads.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is online now  
post #9 of 17 Old 01-28-2020, 07:07 PM
2nd Gear
 
GreatWhiteNorth's Avatar
 
Join Date: Feb 2017
Location: Winnipeg, MB
Posts: 188
PD, the threads are already upsized to 10mm X 1.5, and they're not 100%. I want to do this, repair 'em for a couple of reasons:
- I've got a centerstand on there that I want to take off, which strangely enough had the mounting holes already 10mm dia.
- I don't trust those threads, they felt on the verge of stripping when I installed that centerstand.
- I want to be able to install JNS lowering footpegs, had 'em on my Gen 2, really liked 'em (they're on my spare bike ATM). It'd be a shame to drill out those expensive lowering footpegs to fit.
- I have a couple of spare sets of footpeg brackets, and already have the Helicoil kit, so no extra expense going back to 8mm.

Last edited by GreatWhiteNorth; 01-31-2020 at 07:07 PM. Reason: corrected thread pitch
GreatWhiteNorth is offline  
post #10 of 17 Old 01-29-2020, 04:51 AM
1st Gear
 
Join Date: May 2017
Location: Concord, MA
Posts: 88
For what it's worth, and this is only my experience, I helicoiled mine with M8's after I had an SW motech centerstand on the bike for a season and it buggered the footpeg threads really good. It has held for 2 years with little help from red loctite. I check them every now and then to snug them up but they haven't loosened at all yet. I also have the JNS brackets.

As these guys above have mentioned, it's not the best fix out there but it has worked for me so far.
GreatWhiteNorth likes this.
JTCrow is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

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

Password:


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

Email Address:
OR

Log-in










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
Stripped Oil Pan Bookem 2008+ KLR650 Wrenching & Mod Questions 21 09-13-2011 01:00 PM
Repairing a broken worm gear seat on a hub Buildit 1987 to 2007 Wrenching & Mods 2 02-24-2010 12:13 AM
Stripped! Lockjaw 2008+ KLR650 Wrenching & Mod Questions 18 01-05-2009 08:44 PM
Repairing cracked/broken shrouds on the 08 klr Irish John 1987 to 2007 Wrenching & Mods 4 04-02-2008 10:20 PM
STRIPPED DOO THREAD-Help willows 1987 to 2007 Wrenching & Mods 8 11-30-2007 09:28 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