Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.


Sheared bolt...what to do?

Recommended Posts

2004 Kawasaki Bayou 250.  Changed the differential fluid and was reinstalling the "fill bolt"  (bolt than comes out to let the excess fluid drain) with the 10mm head and it snapped off.  It's not too deep but it is a small bolt.  Suggestions needed on how to address.  I was considering bolt extractor bits but it's such a small bolt I'm not sure that's a smart call.  Thanks

Edited by gt2003

Share this post

Link to post
Share on other sites

You  can get slick guides used to  center  pilot holes for  installing  door hinges.  Replace the right twist drill  bit in the appropriate sized one with a  left twist  drill  bit  and use it to  drill the  broken  bolt. The  bit  guide will  center the drill  bit  and prevent  you going off to the side and messing up the  hole and bolt,  and the left twist drill may extract the bolt as you drill.  If it doesn't,  you will  have a centered  hole in it  to  use a regular extractor on. Here is a link to the  set  I'm  talking about offered  on Amazon.  The set would be handy  for a  lot of projects that require a well  centered  drilled hole .



Share this post

Link to post
Share on other sites

Thanks @davefrombc!  I picked up a reverse drill bit set last night and got it done.  EASY fix.  Thanks for the great advice.


Any idea the size for the replacement bolt?

Share this post

Link to post
Share on other sites

I  can't help  on the  replacement  bolt,  but if you take the threaded part  of the broken one  to  a place selling  metric bolts  you  can  match it up there. According to  a chart I found  a bolt with a 10 mm head is normally  6 mm diameter, and  has a 1 mm thread pitch.

  • Like 1

Share this post

Link to post
Share on other sites

I did just that.  It's actually a 6mmx8mm flange bolt.  Local Kawi dealer didn't have one in stock but I found a allen head 6mm bolt at Lowe's that worked.  I had to throw in a couple of split washers to take up the extra length but it's nice and snug now with no leaks.  Now that I know the actual part # I'm going to have the dealer order it next time they order parts.  Thanks for all the help folks!

Share this post

Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Andrew Baker
      I need help with wiring on a 1998 (I think, 10th digit of the VIN was W) Bayou. I'm not getting spark, I'm pretty sure it is due to grounds being off because the harness is pretty hacked as far as the electric start and charging system goes. I'm needing a good wiring schematic. I found one online and there are a few things that don't add up on it so I'm skeptical that it is really for my year and model. Any help would be appreciated. Thanks. 
    • By Andrew520
      Got a good deal on an 89 bayou 300. Couple questions. First is in the picture I have posted. Note the two wires at the bottom of the pic (white and black/yellow). They were not hooked up to anything and Im not sure if they are supposed to go to the battery or somewhere else and what they are for.
      Second question is I had the carb apart for a cleaning. The vaccum operated slide has a spring under the cap with a plastic clip that goes inside the spring. Is there a proper location inside the spring for that clip. Right now it is just below half way inside the spring.
      It runs alright but keeps fouling the plug. Pulled the plug off, cleaned it and dried it off and it starts back up but not sure how long before itll do it again, last time it was about 20 minutes of riding and it bogged out and wouldnt start.

    • By oxidized_black
      these are what i have in my collection ... always looking for more
      1981 - 2008 ATV HISTORY
      1986 - 2006 Kawasaki KLF300 Bayou Service Manual
      1988 - 2002 Kawasaki Bayou 220 Service Manual
      1994 Kawasaki Bayou 220 Owner's Manual
      1997 - 2002 Kawasaki Prairie 400 Service Manual
      2003 - 2005 Kawasaki KLF250 Bayou Service Manual
      2003 Kawasaki KVF360 Prairie Service Manual
      2004 Kawasaki KFX700 V Force Service Manual
      2004 Kawasaki KVF700 Service Manual
      2005 Kawasaki KVF750 Brute Force Service Manual
      2005 Kawasaki KVF750 Brute Force Service Manual
      2006 Kawasaki KFX80 Specs
      2008 - 2009 Kawasaki KVF750 Parts Manual
      2008 Kawasaki KFX450R Service Manual
      2008 Kawasaki KVF750 Brute Force Service Manual
    • By Ben Lennon
      Hi guys new to this forum and thought I’d jump on as I’ve just bought my first quad a Kawasaki bayou klf300c 89 model. It had starting issues when I bought it so I’ve gone thru and replaced the cdi, voltage regulator and starter solenoid aswell as rebuilt the starter motor after all this it was still free spinning on electric start so I pulled the stator cover off to find the fly wheel wasn’t spinning so replaced the one way clutch bearing put it all back together and still not engaging at all. I’m at a loss and looking for some ideas on we’re to look next to solve the problem
      cheers Ben 👍
    • By JCH
      Hi there
      I am in need of a manual for my KLF 300 Bayou 4x2 . I've found others on here for the 4x4 model, but was wondering if I need a separate 4x2 manual. Does anyone know?
  • Recently Browsing   0 members

    No registered users viewing this page.

  • Create New...