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Posted by: stagg---------------------
Hey everyone, well I bought my first dirtbike and yes you guessed it it's a kdx 200. I 've alot of experience with street motorcycles but none dirt. I am so glad that this website exists because I am sure that someone on here nows the answer to my problem...I hope. So I just bought the bike it's a 96 in mint shape, just needed a new front tire. Well I thought this was a fairly easy task to complete but leave it to me to break somthing, the cover on the right fork with the 4 bolts that keep ot on, I was tightening this up and over tourqued this and snapped off a screw. PLease tell me that this can be replaced. I quickly just put the other ones back on and had to put her back in the shed due to being called to work and haven't had a chance to get back at er.....but have been thinking about it and I can't recall being able to replace the screw, I really hope I don't have to replace the whole right fork for a screw!!!!! Anyone with any help or a mod that I can do to fix this , the cheapest way Idealy!!!! I'll be checking this regularly fairly soon.
Thanks again!!!!!!!
Stagg
Posted by: Crashtheline---------------------
You should be able to remove the broken screw using a form of broken bolt remover device. Just check a hardware store. Some you have to lightly drill at then use something that looks like a screwdriver. Then just check a parts place Google Kawasaki Parts and go to the site bikebandit. Then just get the screw you need.
Posted by: ny kdxer---------------------
Kawasaki part # is 172G0622
Posted by: stagg---------------------
Thats awesome thanks guys!!!!
This site is awesome by the way
Posted by: ebeck---------------------
I assume you are in the US. The tool is called an easy out. Sears sells them. If all else fails, drill and retap or use a heli-coil. Sears also sells tap and die sets and heli-coils.
Most bolts use 12-15 pounds of torque. That is not alot. Carfull with the muscles.
When replacing a bolt use Grade 8 hardware. I replaced almost every bolt on my bike with premuim spec hardware.
I also use blue thread lock on damn near every bolt and nut. Don't use the red.
Posted by: glad2ride---------------------
You are saying screw, but do you mean stud? Four studs are the stock method. Unless someone has broke all four and replaced all four with a screw or bolt, then it should be studs, Kawasaki part number 172G0622 as mentioned. It is a 6mm x 1mm stud that extends out of the hole 22mm. The torque value is 78 inch-pounds, if I remember correctly.
There is also a specific method to bringing all four up to the proper torque.
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