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Is there a fix to repair the stud for the lower chain roller on a 1984 KDX200? The nut/threads snapped when replacing the roller and it looks as though it’s a irreplaceable stud?

Oh wow. I looked on the parts diagram, and that does look like it is the case. I think it needs to have the old one taken off and a new one welded in its place.

It is not part of the case, it mounts "inside" the frame behind the left foot peg. I can't imagine that that would make it so it couldn't be replaced? That roller is important and I really need to repair this thing.

I think Jason meant "does look like the case" meaning yes it appears not to be replaceable. Should be pretty easy to cut off and weld on a new stud if you have access to that equipment if not then a welding shop or automotive shop should be able to take care of it fairly inexpensively
Good luck!

It does look like it is a welded on stud. That is what I meant. As in, that is the situation, that is what is going on.

I would suggest Grade 8 bolt over grade 5.

cut it off
grind it flat
sand it down
weld on a new stud

Ok thanks for the help! I was hoping the stud could be unscrewed or something but looks like I will try my welding skills out. I bought this bike complete in what I think is nice original condition for $225. Don’t want to fully restore just a Sunday trail putter around the yard so to speak.

Thanks for the follow up. Without seeing pictures, it is hard to diagnose. On a trail bike made 34 years ago, that may have been the way it was made. If it was removable, then I am confident it would be on the parts diagram.

You may get bit by the "dirt bike tinkerer" bug like many of us and want to continue updating and improving it.

I've been into bikes for the past 17yrs lol, so I can relate to the tinkering bug...however my wallet does not appreciate it

On TT, it kind of sounds like you are going to ride it without the roller. Would that not hit the frame?

When I had it fired for the first time I rode it briefly for a couple minutes but now that I purchased rollers, it will be fixed before actually ridden.

OK. That is good. I have seen frames and swingarms ground down because of the chain hitting them.