So a couple of days ago im up my bud's garage puttin my bike back together with a new set of rubber and some drivetrain maintenance parts (replaced sprockets/chain). As i was putting the front end back together i kind of slightly over tightened one of the bolts that hold the front axle clamp mabobby on (set of 4 that hold the front axle in place). This rewarded me with a loud "snap" and a broken stud for my troubles.

Heres where it gets interesting. Once i got done yelling some choice words due to the fact that my bike is now stuck on the stand (!!!!!) and all forward progress came to a complete stand still because i cant move the bike to finish it i talked to my bud (service manager at a stealership). He told me hed hook me up with a replacement the next day. Next day comes and i call him at work..... Kawasaki does not sell a replacement stud. wtf?!

Looks like we are going to have to pull a good one and try to match it up with a different make/model. Ill try to remember to reply to this once i have details on what works.

 

lol at "stealership". Bad luck about that man, hope u can work out a solution.

 

I did the same thing, it's an easy fix. Go to the hardware store and get a long metric bolt take the nut to make sure you get the right one. The stud is screwed in so just screw in the bolt then hack saw off the excess.

 

Here's the solution.
you get a bolt, M5 or M6 X 50mm (not sure what size it is.) You remove the broken end of the stud stuck in the fork leg. Replace the broken stud with the bolt with some locktite on the end. (Addit. Before fitting the new bolt add the original nut and spin it hard up against the bolt head.) Tweak it up (only 9.8 NM torque, it wont snap with this torque.) Leave it for 6 hours for the Loktite to go off. Trim the bolt off between the head and the nut. Now refit the clamp and torque all the nuts up to 9.8NM in sequence, Should be a 10 minute job + six hours for the Loktite to go off.

 

It works I have do it