I just bought this 2024 kx450x brand new a month ago. Kawasaki had a great deal to close out the 2024 models.
First oil change, the top oil filter bolt, the long one, snapped off down at the threads.
I have been doing most of my own rebuilds, repairs and maintenance on all my bikes and auto’s for the past 40 years and learned a long time ago that proper torque wrenches are mandatory. I don’t use cheap sets of Chinese tools. The torque recommendations for these 2 bolts for the oil filter cap are a bit higher than 100in/lbs. I started around 80 on both, moved up to 90, then 100. The bottom hit 100 no problem, the top went a bit further which I expected due to the longer bolt. Before it clicked at 100 the damn thing snapped off.
Now, the KX has no warranty. Your screwed the minute you drive that thing off the lot. I plead my case with the dealer and they agreed to “take a look at it” for free and maybe submit a case to Kawasaki to consider.
I’ll keep this post up to date but wanted to warn everyone that this seems to be a common problem with that long 3” bolt. Maybe they need to review their torque specs and drop it down to 85?
100ilb, sounds like a lot for that small diameter bolt,
I agree. Just going by the book.
I just do mine by feel. I own several torque wrenches, and frankly, I don’t trust my 1/4 drive one that measures in inch/lbs.
I just snug them by hand. If you take the outer case cover off, should be able to get it out.
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I’m a feeler too. I have a calibrated hand
That’s the plan.
I told the dealer to do what they can under “warranty” and if they decide they want to charge me then to forget it, I’ll take care of it myself.
🤣
Mine doesn’t appear to seal great. It always has some dirt and dust behind the cover.
I snapped mine on the first oil change too. Just ran it to the dealer and they got it out without taking the case off and I still have no idea how.
But yeah the tech told me just hand tighten with a tiny socket wrench or t-handle.
Working on dirt bikes is nothing compared to salt water outboards. Nightmare!
I can only imagine. I’m surrounded by the Great Lakes. Outboards aren’t really a problem. The winters, salted roads with massive potholes and corrosion take an equally heavy toll!
That is a serious problem. No dust/dirt should ever get in there. Make sure that o’ring is in good shape and not pinched. Mine was a bit tricky to get the cover on without messing with that ring. Oil it and give it a little twisting action as you seat it.
that's complete ass...i would recommend getting an aftermarket oil filter cover that does not have the little metal inserts in it, just a one piece. Also the top oil filter bolt goes all the way into the engine & i've had it happen 2x (once on a 23 & once on a 24) where the inner clutch cover gasket starts leaking due to the bolt going in & out. This is ridiculous situations for 2024 motorcycles to have.
8-9 ft-lbs (106 in-lbs) is what most of the oil filter cover bolts for all the models are spec'd to and should not snap a 6mm bolt off. Did you lube the threads, was the cap flush up against the cases (if not it can bind), do you have another torque wrench to check you calibration?
If you want an aftermarket cover DM for a discount code.
Careful bro, might mess with your chassis flex characteristics.
I guess ya got a 50/50 chance that will help or hinder
I had exactly this happen twice, once at work on a bus, and once on a Gasgas engine mount. I basically refuse to use a torque wrench on anything less than 15ft lbs. below that it’s by feel.
The small stuff is just too sensitive to not trust my gut.
I hear ya. I’m trying to do the right thing by following the manufacturer so I don’t break any more shit. Once I get past this, my plan is to reduce the amount of recommended torque by about 25% and see how that works. I’m also going to get another torque wrench from a different manufacturer so I can compare how closely they match each other.
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