One of the bolts securing the axl holder on the front fork broke. It appears to be a factory defect and broke while being torqued during manufacturing. So basically I've been driving around with only three bolts for a long time. Is there any way to fix this without getting a whole new expensive fork?

 

Those studs break very easily the torque on them is something like 6.5 ft/pounds. If you have enough thread left on the stud you might be able to lock 2 nuts together and get it out, some guys have been lucky and got them out with vise grips. Or you might have to buy a stud removal tool. Then you should be able to source a new stud at your local bolt supply place. Good luck.

 

Wow that's weird. I've only had to loosen them to take off the wheel, and I don't use a torque wrench on anything. I don't trust them except on the internal stuff on an engine.

 

I'd spray with a penetrant ((PB blaster) and let it soak for a day or two, then gently warm the alum (not the stud) w/ a torch.. a hundred degrees or two not melting the thing apart.. then get the vise grips and give it a twirl.. good luck.

~steve

 

Like revtor said heat it gently you can use a propane torch. Keep the tip of the blue flame away by several inches and continuously move it in circles around the broken stud, heating the aluminium. Once it is hot use a Snap-On or similar stud remover. The heat expands the aluminium faster than the steel stud and also softens any locktite that may have been used.It should come right out.

 

Kawi doesn't sell the studs separately. Go to a Honda dealer and get one for one of the older XR.

Ride on
Brewster

 

Just use a bolt. Thread a nut onto it, wind it in until it's snug (use some loctite too), then cut off the bolt head. Hey presto! One new stud.

 

I replaced 2 of mine with exhaust studs 6 x 35mm

 

Thanks for the ideas guys. I never would have known about the broken stud if I hadn't changed the front tire.

So is the stud just a bolt threaded on both ends? I looked at the Kawi parts diagram and saw that there was no seperate part to fix this problem so I started to panic.

I then used a dremel to grind the corner of the axle holder so I could put the bolt back on what remained of the stud. At least that solved my immediate problem but I'll try to remove the stud and replace it with a long bolt and cut the head off as WestOz suggested.

So again, is the stud a bolt threaded on both ends? Here's a pic of the temporary fix.

 

Wow!?!

What made you do that?