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On my '95 KDX 200, the previous owner apparently held stock in a zip-tie company as that appears to have been his hardware answer for anything plastic on the bike. I have new side panel, shrouds, fenders, etc. , in-bound but I don't think I have a single OEM bolt on the plastics to get an indication of what size I need to obtain. Especially on the side panels and radiator shrouds; can anyone please inform me of what size bolts I will need? I'm fairly certain they'll be metric, but I'd rather know for sure and get the right ones in the first trip.

Thanks,

John

Metric for sure. I want to say they are 6mm bolts (8mm heads) but I am not about the lengths.

metric, but they are all of different length.

Maybe one of the online parts fiche sources would help, like http://www.kawasakipartshouse.net

They are definitely 6 mm thd. I have found these bolts hard to come by. You might have to buy some sort of hardware kit. I've seen them on Ebay for about $15, IIRC.

I'd be willing to measure the length a few key ones for you if that would help.

turtle wrote:Maybe one of the online parts fiche sources would help, like http://www.kawasakipartshouse.net

They are definitely 6 mm thd. I have found these bolts hard to come by. You might have to buy some sort of hardware kit. I've seen them on Ebay for about $15, IIRC.

I'd be willing to measure the length a few key ones for you if that would help.

Thanks, I'd appreciate any help that can be offered!

From that site, it looks like I need 6x20, 6x12, and 6x25 to do the job along with some collars.

RockyMountain ATV sells assorted 6mm bolt kits for $15.99. You get several different lengths.

RMA bolt kit

Coop wrote:RockyMountain ATV sells assorted 6mm bolt kits for $15.99. You get several different lengths.

RMA bolt kit

Thanks for the link. If I can't find them locally, I'll go that route.

My local Ace hardware has a good selection of metric flange bolts

Mr. Wibbens wrote:My local Ace hardware has a good selection of metric flange bolts

Closest to me are Northern Tool and Lowe's, but there are some Ace Hardwares too. I figure between them and a slew of auto parts stores, I should get lucky.

Mr. Wibbens wrote:My local Ace hardware has a good selection of metric flange bolts

Same here. The one downside is that the head of the same size bolt will be different than what came on the bike.

Tedh98 wrote:

Mr. Wibbens wrote:My local Ace hardware has a good selection of metric flange bolts

Same here. The one downside is that the head of the same size bolt will be different than what came on the bike.

lol, that won't be a problem for me! I don't think it has an original bolt in the plastic anywhere.

You could also get allen head bolts

Mr. Wibbens wrote:You could also get allen head bolts

I usually switch to allen heads when I buy locally because I can never find metric flange bolts. Ace, Lowes, Napa, nobody around here has them. I prefer an allen head over the larger 10mm bolt heads that are always on the bolts I can find around here lol.

But anyway mismatched bolts is a common "issue" on used bikes. I do my best to either use the correct bolt or change them all to the same head. So if I use an allen head on one fender or side cover bolt, I replace them all with the same one so it takes one tool to remove it. I am confused why my 2003 side covers have 3 8mm socket heads and one phillips head cam type. Why?

I converted mine all over to flanged SS allen head, and it's sweet to be able to use a T wrench on them. I got them from Decatur nut and Bolt co when living in IL...LOL. Regardless a specialty store like this is likely to have whatever you want.

Get this

http://www.bobscycle.com/browse.cfm/4,106687.html

You'll be able to replace most every bolt with it. I keep the cheaper one (20 bucks) in the garage for lost bolts etc. They are exact copies of the originals. Nothing is worse than having different size head on everything.
I'm a big 8,10,12 man.
They also make them for KTM's.

Yes, the 6mm bolts with 8mm washer heads can mostly only be found at motorcycle specific shops and websites, 6mm bolts with standard 10mm heads can be found at almost any auto parts or hardware store.
Like others here, I like to maintain my bike with the correct hardware. Over the years, I have collected a large jar of 6mm fasteners. It comes in handy all the time. Now, whenever I come across a "dead" bike, I look for fasteners that I can strip from it for my collection.
In looking for a new, used bike, I always check it over for oddball fasteners. Nothing quite sucks as bad as having multiple size and style fasteners all over your bike.
BTW- 8mm bolts with 12mm heads are similar in availabilty. All you will find in auto parts stores and hardware stores is 8mm bolts with 13mm heads...and they will throw delays into your maintenance work every time.

I was just at Ace, they have flange bolts in both standard and small head sizes

But I liked the ss pan head allens better

That figures. I do not have an ACE Hardware store anywhere near me.

gregp wrote:That figures. I do not have an ACE Hardware store anywhere near me.

Ace is the place... Sorry

I measured some screws.

Each rad shroud: 10 mm (2 screws into gas tank); 25mm (screw at lower front near radiator)

Each side panel uses 20 mm screws. My LH side panel has a cam type screw as well. Is this stock?

HTH.