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I broke off one of 4 axle pinch studs on my kdx 220 (need to invest in a inch/lb torque wrench :banghead: ). It is the upper one closest to the hub.

2 Questions:

1. Are those studs that can be replaced? Or are the all one piece molded with the fork tube?

2. Is it safe to ride the bike with one of these missing? There is still one upper and two lower holding the axle pinch clamp there.

Thanks In Advance

Should be ok to ride........

You are not alone! I broke one of the pinch bolts off as well. Yes, it can be fixed. Use some penetrating oil on the pinch bolt where it goes into the fork leg. Use a vise grip and unscrew the bolt. It comes out counterclockwise, just as you would expect. Do the same with one of the good bolts, so you can take it to a dealer (or hardware store) to try and match it. You will need the good one, since the broken one will not give you a correct size.
Kawasaki does not list a part number for the bolts, they would rather you buy an entire fork leg.
What I thought was a disaster turned out to be just a minor inconvenience.
We have a smart, experienced parts manager here, and he was able to find a barrel bolt that matched almost perfect - just a hair longer than stock. You could use a regular bolt, but they are not as strong as a barrel bolt. Of course, a regular bolt would be stronger than having nothing.

I can't get a photo uploaded on here, but pm me if you want a photo of the bolt.

I have used a long set screw from a bolt supply store to replace these before. Don't forget the loctite!

The problem with using a standard bolt is, you may run it in to deep and damage the threads in the bottom of the hole. Then when you remove the bolt the threads come with it.

By using a set screw you can loctite it and feel when it bottoms in the threads, let the loctite cure and then install clamps and nut. Plus you can hold it with an allen wrench when you remove the nut so the set screw stays in place.

Of course OEM stud would be better if you can find it!

It happens all the time - it's very rideable as is but the replacement can be picked up at your local hardware store.

Go to your Kawi dealer and have them search this part # for the stud

172G0622

I found this somewhere, sometime, from someone. Don't remember where.

Give it a try, I've never checked it out cause I've never snapped one off.

You should invest in a in-lb torque wrench

Sean

Yeah I ordered a couple of those studs. THey are only 70 cents each. I will ride it like it is until they come in then replace the broken one. Thanks! I will definitely also be getting an inch/lb torque wrench.

My local Kawi dealer tried to charge me $10.50 for that bolt and I'd have to wait 4-7 business days for it to be "shipped" in from the California "warehouse."

Ace Hardware, instead. Or you can pick up one of those "Japanese Dirt Bike bolt kits." for $11 at a fraction of the per-bolt price from "the warehouse."

Rick

AZRick: You DO know you got bent over, right?

I have one'a those studs in my tub-o-stuff (not of much use on USD forks)..and it cost less than a buck...from the local dealer.

Didn't look, but...what is it? Something like 18in/lb? Not much!!

Do insure your put it together so that there is NO gap at the top.

The gap is at the BOTTOM! So...snug the TOP nuts first.

Yeah actually the manuall says 87 inch/lb

Yes what I do is tighten the top nuts halfway, then compress the forks a few times to align them. then tighten everything up.

I ordered two of the studs from bike bandit. I think it came to $6 something including shipping

Yeah....87in/lb sounds good.

I should'a not said anything having not looked it up myself.

Thanks for posting the correct torque!