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Discussion Starter · #1 ·
Hi all, so apparently previous owner threaded and glued bolts in place, and one gave way, fell out and lead me to discovering this was the case with a few of them. 😡

Anyhow… I have the thread repair kit (went with HHIP over Helicoil) and I have all of the bolts still

BUT…

I’m missing this big long one (see image) and want to make sure I get the right bolt ordered first time.
Gas Auto part Nut Metal Motor vehicle


Anyone know the part number or where I can source one with Allen/hex head please?

Thanks in advance!
 

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2002 KLR 650
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Since that long bolt goes into the case and you'll have to remove the clutch cover and a bunch of other stuff, be sure to have new gaskets ready. Oil and filter. Radiator fluid. This is an excellent time to clean your little oil screen behind the clutch cover. Clymer's Manual. Have you ever removed and installed the clutch actuator ? Special procedure !
 

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3D has your stuff. Might be hard to find just 1 bolt though. The length is the tough part. Specialty hardware warehouse in L.A. ? Standard 6 x 80 allen bolt.



 

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Anyone know the part number or where I can source one with Allen/hex head please?
The previous owner apparently replaced all of the 8mm hex-headed bolts with 5mm allen-headed bolts.
Might take a little searching at local hardware stores to find one long enough with allen head.


Just a side note, does your bike have oil in it?
That brake switch spring looks very odd, is that stock?
It is, on a Gen1 bike without a kickstart kit.
 

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KLRs: 2013, 2005, 1998; 2017 HD Electraglide Ultra
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You probably know this, but let me reinforce it anyway: When you install the thread repair, make sure the insert is BELOW the level of the case surface. Sometimes they don't go all the way in. Grind off any extra poking above it.
 

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Discussion Starter · #9 · (Edited)
Just a side note, does your bike have oil in it?
That brake switch spring looks very odd, is that stock?
Sure does have oil in it AND on it! The stripped thread meant I lost that bolt while others didn’t seal properly AND squirted a healthy amount of synthetic all over my boots. 🤦🏽


And yes, spring is being replaced. There’s an overhaul under way up in here. 😂🤦🏽
 

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Discussion Starter · #11 ·
Since that long bolt goes into the case and you'll have to remove the clutch cover and a bunch of other stuff, be sure to have new gaskets ready. Oil and filter. Radiator fluid. This is an excellent time to clean your little oil screen behind the clutch cover. Clymer's Manual. Have you ever removed and installed the clutch actuator ? Special procedure !
Spot on, already done it once, about to do it again! The first time was when I learned (on the test ride) that a some of the bolt holes were threaded, hence the oil on the clutch cover… and my boots… and my jeans … and my dignity 😂😭🤦🏽
 

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Discussion Starter · #12 ·
3D has your stuff. Might be hard to find just 1 bolt though. The length is the tough part. Specialty hardware warehouse in L.A. ? Standard 6 x 80 allen bolt.



I have the gaskets, that exact kit from 3D but there’s no long bolt, I have some more info from this thread now so will jump on to those next steps!
 

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UPDATE: belmetrics have one for $0.65 (couldn’t find it on RMATV/MC)
You have to log-in & then go to OEM Parts on Left end of screen at RMATV/MC.
They use "Hot Spots" on the parts & one can immediately check price & availability. Super convenient.

Many times I simply want simpler access to parts diagrams. So I use Babbits On-line / Kawasaki Partshouse diagrams.
They also have a "Parts Search" function at the bottom of pages, which RMATV does not have. Super handy to use.

RMATV uses Descriptions for parts pages. Can be frustrating to find proper page, especially between different brands of bikes.
Babbits uses Thumbnail pics, also super handy to find proper page.
Many times I have both sites Open.
 
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