Fork/Axle Lug Repair

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10/21/2018 11:56 AM
Edited Date/Time: 10/21/2018 11:56 AM

Hello brothers! Asking for your advice here. I own a kawasaki kx250f 2009 with stock forks.
Came home from a ride, washed the bike and saw that one of the bolts that are holding the fork guards is bent. I know that this is something common and that also, the previous owner used helicoil to solve this problem but, when I took the guard off I saw that the thread is absolutely blown... What would be your advice fixing this? Thank you very much!

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10/21/2018 12:08 PM

Remove the lug from the lower fork tube. Weld it up and remachine. Use a die grinder to bring the original shape back.

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10/21/2018 7:12 PM

Weld as is on bike. Lay bike over and put small round aluminum spacer inside hole up against unbroken part.
Weld spacer in place quickly and be ready to cool fork lug with cold wet rags.
Drill center of spacer and tap. Side panel spacers are a good size and already have a center hole.
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10/21/2018 9:33 PM

That pic is after a wash?? w00t w00t

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10/21/2018 10:59 PM

Is that a crack across the "TEN" at the bottom of the lug? And how big is that hammer you are using to beat in the axle?? Seriously tho - go on eBay and find a new/used set of forks for that bike, for cheap. Easy to find.

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10/22/2018 8:40 AM

Looks like a crack to me but its hard to say looking on the phone.

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10/31/2018 8:31 PM

Purchase a new lower fork leg is clearly the best way of going about it but I know those things aren't cheap. Or Like other posters said you need to weld up the material that broke off, then re drill. When it comes to that I would recomend a time sert...keeps every thing the same and will hold up much better than a heli coil.

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