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Old 06-12-2011, 01:08 PM   #2881
EdGear's Avatar
Joined: Oct 2008
Location: Bay Area, CA
Oddometer: 543
There have been several threads about replacing the battery cover bolts with threaded studs, to make it easier to remove and replace crash bars.




What I noticed was that when you tighten the lock nut version of the stud, like Qwik/Geek, the battery cover becomes fixed making starting the lower tank bolts difficult. What I tried was an M8x40 SS set screw. I was able to tighten the stud using the hex socket in the shaft. Unfortunately it was too short to work with the HB spacers so I cut the heads off some long threaded SS M8 bolts. I used the lock nut method to tighten the loctited studs, then I removed the lock nuts. I used blue loctite so I would be able to remove the battery cover in the future. I let the studs set for 30 minutes. I used the spacers provided with the HB crash bars with nylocks. During the final bit of tightening I did notice the stud move. When I remove the nylocks the studs may come out, no big deal. I'd like to find 50mm M8 set screws to replace the home made studs.

From Hontri I got the idea to drill through the lower tank, battery cover. No more wondering where that clip nut is. I used an M8x100 bolt.

The left lower tank bolt was still a bear to start. I used a floor jack to apply upwards pressure on the lower tank to start the bolt through the battery cover. I later found another inmate had suggested this. The other inmate suggestion I used was to loosen the upper fairings. Thanks.

2010 KTM 690 Enduro R
2006 KTM 950 Adventure S
2002 KTM 400/453 EXC
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