2004 KDX 200H Upper shock bolt and nut?

[AzKdx]

While riding my upper shock bolt must have rattled out as I went to load it up the following day to go out again and found out uh oh no bolt. I’ve looked at parts diagrams and only seem to find a bolt, but no nut. Does anyone know the part numbers so I don’t order the wrong thing? Or better yet is there a bolt and locknut I could get at ACE or Home Depot that would fit in there just right? Also while it’s out is there a bushing that may have fallen out that I should look into ordering too?

Here’s pictures, not sure if the ones I uploaded with the post are showing



Thank you guys so much

[billie_morini]

AzKdx, I can help a little. The bolt is 10 x 44 mm (see annotated screenshot made from microfiche at Rocky Mountain ATV website). I don't think a nut is required. I'll check my KDX shop manual and peek at my bike in a little bit. I haven't forgotten you also asked whether a bushing is required.

[billie_morini]

here's a photo of the top of the shock. You can see a metal sleeve within the rubber bushing (annotated photo).

FYI: top & bottom shock bolt torque is 29 ft. lbs.

[billie_morini]

No nut. Just bolt from right side. Here is photo from left side. Receiving threads are welded to frame.

[billie_morini]

if you only need bushing inner metal sleeve, then it's possible to find a sleeve or stiff tubing at really good hardware store. If you need entire bushing, then you are looking for a KYB part. I don't know dimensions. However, it is possible to locate them by model. Here is an example marketed by All Balls Racing found at:
https://www.partsgiant.com/p383290-all- ... gKTF_D_BwE

[AzKdx]

AzKdx, I can help a little. The bolt is 10 x 44 mm (see annotated screenshot made from microfiche at Rocky Mountain ATV website). I don't think a nut is required. I'll check my KDX shop manual and peek at my bike in a little bit. I haven't forgotten you also asked whether a bushing is required.

Thank you, that is the part # I found too, but I was looking and I couldn’t tell where it thread into so o assumed a nut would have to be on the other side so I assumed I must have the wrong diagram

[billie_morini]

AzKdx, you're doing fine. Since the bolt size is known, it is possible to get one at a hardware store that has a good metric selection. I didn't see your photos until later. Yup, you need a bushing. Info for that was provided.

Any new bushing needs to be driven straight. If you don't have the tools to do this, then take the parts to an independent motorcycle mechanic or a machine shop. They will use a press capable of applying equal force across the bushing face. If it were me, then I'd buy two because sometimes a bushing gets messed up when install goes poorly.

[AzKdx]

No nut. Just bolt from right side. Here is photo from left side. Receiving threads are welded to frame.

thank you! I just didnt want to pay shipping twice and thought id double check with you guys first.

[Chuck78]

I believe that's an inner bearing race, not a bushing... Best to buy OEM or aftermarket replacement vs trying to fabricate and harden something else to fit the dimensions. Look inside the shock's upper eye mount to see if it's a needle roller bearing, or if it's a spherical eye bearing. The spherical eye will just take a spacer on either side, but the photo above from All Balls makes it look perhaps like a needle bearing, but it could be either. I know for a fact that Showa shocks on RM vs DRZ use both styles, needle roller and spherical eye, as I have several 50mm Showa shocks on the bench now building a hybrid FrankenShowa combo for the KDX220R's

[KDXGarage]

Can yu try again on posting a picture? Look at my signature below my post on how to post a picture. I can not see your attempted picture.

I assume the bolt fell out.

Research a torque wrench.

[billie_morini]

Chuck,
we are both correct. The component in the shock eye is a bearing. Specifically, a sleeve bearing. Sleeve bearings are also called bushings. So, a bushing is a special (and simple) type of bearing.

We also agree that the best course of action is replacement of this sleeve bearing / bushing because it looks pretty wallowing out.

I had the KYB shock for my KDX 22O in my hands quite a bit when I internally shortened the stroke to lower the bike. My recall is the inner metal portion is nothing more than a sleeve (journal). I do not recall seeing needle bearings there. In contrast, I distinctly recall needle bearings in the lower shock linkages (dog bones).

[Chuck78]

Chuck,
we are both correct. The component in the shock eye is a bearing. Specifically, a sleeve bearing. Sleeve bearings are also called bushings. So, a bushing is a special (and simple) type of bearing.

We also agree that the best course of action is replacement of this sleeve bearing / bushing because it looks pretty wallowing out.

I had the KYB shock for my KDX 22O in my hands quite a bit when I internally shortened the stroke to lower the bike. My recall is the inner metal portion is nothing more than a sleeve (journal). I do not recall seeing needle bearings there. In contrast, I distinctly recall needle bearings in the lower shock linkages (dog bones).

The Showa 50mm shocks definitely have spherical eye bearings or needle roller bearings in the upper eye (depending on bike model or year perhaps), but I can see the KDX simply having just a bushing/sleeve bearing in the top while having needle roller bearings on the bottom, as it's an older design and the lower bearing sees significantly more movement than the upper. Additionally, a more stationary bearing subjected to lots of hard compressive forces would become quite notchy with wear, whereas as a spherical eye bearing (or sleeve bearing) would evenly distribute the shock load forces vs a needle bearing having only contact on the rollers.

I'll keep this in mind... The significantly lesser movement of the upper makes me lean towards the spherical eye bearing of the '98 Suzuki RM125/250 Showa shock body vs the '01-'04 RM125 needle roller bearing upper eye parts.

Thank you sir for sparking this analysis in my overly analytical head!

[billie_morini]

AzKdx & Chuck: like this! And it's for 2004 KDX 200. I misread the subject as "220." Sorry, I've been sick and hope I've not caused problems. Link below is one place to buy.

[billie_morini]

www.amazon.com/All-Balls-Bearing-Kawasa ... B07RJTG7X1

[AzKdx]

www.amazon.com/All-Balls-Bearing-Kawasa ... B07RJTG7X1

thank you Billie, the bolt gets in tomorrow, Im going to install it take it for a ride over the weekend see if it loosened midway through then again after i get home. I'll check the bearing when i go to install the bolt. I really hope i can avoid replacing that as I have to take bike more apart than id like to with no garage. if/when i do take the rear shock out i need to put a seal kit in it as it has a slight leak. if i'm reading right, there's also a bearing of sorts in the lower shock connection as well, the bolt seems tight on the lower attachment point, but there is slight play left to right so that's probably not a good sign either.


a little info on the bike, I got it for 700 bucks, it runs and drive but looks beat to hell. I took it to the motorcycle shop for a once over he recommended I just ride it instead of dumping lots of money into it, but did a couple little things to it.

[KDXGarage]

The bearing that is the little one in the linkage gets worn earlier than the other ones. Check it. If the bike is beat to hell, then it is probably shot.

[Trackdog]

www.amazon.com/All-Balls-Bearing-Kawasa ... B07RJTG7X1

a little info on the bike, I got it for 700 bucks, it runs and drive but looks beat to hell. I took it to the motorcycle shop for a once over he recommended I just ride it instead of dumping lots of money into it, but did a couple little things to it.

What does a "rideable" $700 '04 look like?

[KDXGarage]

I have bought some $200 bikes that were rideable. I just pushed them to the top of a hill, hopped on and rode back down. Easy.

[billie_morini]

I have bought some $200 bikes that were rideable. I just pushed them to the top of a hill, hopped on and rode back down. Easy.

That's funny!

[AzKdx]

www.amazon.com/All-Balls-Bearing-Kawasa ... B07RJTG7X1

a little info on the bike, I got it for 700 bucks, it runs and drive but looks beat to hell. I took it to the motorcycle shop for a once over he recommended I just ride it instead of dumping lots of money into it, but did a couple little things to it.

What does a "rideable" $700 '04 look like?

lol, I’ll have to snap a pic of it. Last ride after I got that shock bolt back in (which by the way I just found the old one in my driveway lol) it started smoking way more especially under load (for mix I’m using motul 2t oil @ 40:1) so I inspected the oil check window by the clutch cover it wasn’t showing at the window so I suspect I lost my crank seal. I feel like every seal and bushing needs replaced after going on 21 years in the desert and mostly sitting in a garage for 6 years.