2001 KX250 problems...

[DSsuper92]

I bought a left over 01' KX250 last month and haven't even to fully break it in yet. However I have done some minor saftey things like threadlock bolts that need it. Wondering if anybody has had this happen to them.

I went to unscrew the bolts that hold the rad shrouds onto the gas tank and they wouldn't come out. They would turn but not come out. I took the tank down to the dealer I got it from a month ago and they are trying to warranty the tank for me. The threads had stripped the inside of whatever holds them in place. Now I didn't over tourque them since I never felt any resistance when tightening them after applying some threadlock when I first got the bike.

Also alot of the bolts were extremely hard to get off at first. Sort of like the factory had used to much force in applying them. Has anybody out there heard or have had this happen to them?

Thanks,
Dave

 

[Senior KX Rider]

I put anti-seize on the threads of those bolts. They are notorious for spinning the inserts in the tank.

 

[DSsuper92]

Just got off the phone with the dealer. They're going to warranty it if they find out I didn't "cross rut" the threads. I'm not even sure how you would do this. They have to destroy the tank to do so. I feel like I'm about to get screwed big time.

 

[Blade]

Loc-tite is a no-no on inserts in plastic. The bolt and loc-tite will have a stronger hold on the insert than the plastic tank does.

 

[Senior KX Rider]

Thats right:D

 

[DSsuper92]

Lesson learned. However, the right side came out as easy as pie. The left side was the one that spun the inserts. That is until I put the right side back on. As soon as I got it on it spun the insert.

I'm beginning to miss my Honda. :(

 

[Camstyn]

Don't worry 'bout it, I've spun both of mine on my '00 KX250. Both from cross-threading the bolts in the inserts. Damn faulty 8mm sockets..

Kawasaki does not have a part number for these inserts, but a CR uses the exact same inserts, thread pitch/length/diameter and all. You can order the tank inserts for a CR if yours are toast, and a good mechanic can drill yours out and epoxy the new ones in so it's as good as new.

Careful with those sockets!

 

[dix]

Can't say that I have run into that problem yet. You'll love the bike as soon as your initial bad luck passes! In the back section of your owner's manual is a list of nearly every bolt and nut on the bike, and the appropraite torque setting for each. Be sure to follow them carefully, as some are supposed to be torqued very lightly. I use a torque wrench on nearly everything, saves a lot of stripped bolts and problems such as yours. Also, the shop manual for that bike lists what bolts are in need of loc-tite and which ones to lubricate.

 

[smooth sail]

As stated, no Loctite on bolts that thread into inserts in plastic! I limit my use of Loctite to things that could be a real mess if they got loose during a ride: disks, caliper mount bolts, shifter bolt, etc.,and then only the blue "breakable" kind. I love my KX, (2000 model) and I use lots of anti-seize. Rad shroud bolts, cylinder studs, and especially chain adjuster studs. If you haven't done it, pull the shock linkage, and steering apart and lube the bearings in both places. These were practically dry on mine. A good waterproof grease (I've used both Redline and BelRay- both are OK in my book) will make a difference in the longevity of the bearings.
Smooth

 

[dix]

Wait a minute! You have a 2001 KX 250 right? If so, then you can't possibly have any problems!

 

[Camstyn]

And if you do, Kawasaki doesn't want to hear about it. They already got your money.

 

[dix]

You've got that right!!