Question about 2002 kawasaki KX 500

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The chain adjustment bolts have broke off and i cant get them out. they just stopped when i was trying to pull them out. and i dont want to take it to a shop that will charge a arm and a leg for two little bolts. can anyone help me out?

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If they broke of but still have the bolt sticking out just use a stud remover or get two nuts and screw the first nut on and screw the 2nd nut tight to the first one then use the first nut to loosen, or Rockymountainatv.com sells kit for that.

Posted on Oct 04, 2009

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Try and drill them my ownly solution good luck

Posted on Apr 03, 2009

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1 Answer

How to fix my alighnment


Provided you have not been in an accident that has bent your frame,upper and lower triple tree, or forks, the only alignment you can make is to adjust your chain. If the the front wheel is not tracking with the back wheel you just have an improperly adjusted chain. On each side of the swing arm by the rear axle are two chain adjuster cam/wheels. The have numbered bump/stops. Both chain adjusters should be set in the same numbered bump/stop to align the front and rear chain sprockets and the front and rear wheel tracking. the adjusters are on the machine for the purpose of setting the amount of chain slack. Your chain should not be too tight or too loose. If you grab your chain in the middle and push it up and down, you should have a slack measurement of 1 1/4 inches from the bottom edge of the chain to the top edge of the chain. If the setting is off the best way to make the adjustment is to raise the rear wheel off of the ground. A race bike stand is very helpful for this and oiling and caring for your chain. Harbor freight tools sells a cheap rear stand for about $35 (buy the cheaper one piece non-collapseable stand). Pull out the cotter pin, loosen the axle bolt, turn both adjusters till you have the correct amount of slack and they are both set to the same number. Tighten the axle and recheck the slack. If you notice when spinning the rear wheel that the chain goes tight then slack, you have a stretched section of chain. If this is the case you should replace the chain and any worn sprockets at this time.

Aug 17, 2011 | 2005 kawasaki Ninja 250 R

1 Answer

How to adjust primary chain and clutch on 04 1200c thanks


First, let's adjust the primary chain first. Remove the upper inspection hole cover. Stick your finger in the hole, find the chain, and raise and lower it. With the engine cold, the chain should have 3/8" to 1/2" up and down movement. To adjust this, look underneath the primary. You'll see a bolt and a lock nut. under the primary. Loosen the lock nut and turn the adjuster to adjust the tension in the chain. Adjusting the bolt upwards tightens the chain, lowering it loosens the chain. If you get the chain too tight, lower the chain until you get too much movement in it and then raise the adjuster again.

On the clutch, remove the clutch release mechanism cover. Remove the spring and the lock nut. Find the cable adjuster in the middle of the clutch cable. Move the cover up or down, break the lock nut, and adjust the cable adjuster inwards until you get a lot of slack in the cable. Turn the adjuster bolt at the relaese mechanism counterclockwise until it stops. Then turn it back clockwise 1/2 turn. Install the locknut and spring and cover. Go back and adjust the cable adjuster outwards until you have about an 1/8" freeplay. Lock the lock nut and replace the cover.

Good Luck
Steve

Dec 19, 2010 | 2004 Harley Davidson XL 1200 C Sportster...

1 Answer

Clutch cable wont work. came loose on inside of cover


Are you sure it just came loose? More than likely, it broke. To find out, drain the primary oil and loosen the locknut at the cable adjuster on the outer primary cover. Turn the adjuster inwards as far as it will go. Remove the four screws on the derby cover. and lift it away from the primary cover. Remove the spring and the locknut.

Now, remove any footpegs or anything else that may be in the way of the removal of the outer primary. Loosen the locknut on turn the primary chain tensioner out on the bottom of the primary cover. Remove all the bolts from the primary.

Now, turn the clutch adjuster screw back at the derby cover in a clockwise direction and remove the outer primary cover. With the primary cover off, you can replace the cable if necessary or simply hook it back up.

Reassemble in reverse order. To adjust the primary chain, turn the adjuster bolt upwards until you have 1/2" to 5/8" up and down slack in the top run of the primary chain. To adjust the clutch, turn the screw counterclockwise until it stops. Then, go back clockwise 1/4 turn and install the locknut, spring and the derby cover. Then adjust the cable adjuster out until you have 1/8" freeplay in the cable.

Good Luck
Steve

Oct 01, 2010 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

Okay. Thanks to Guru, the handlebars were easy to fix. Maybe shouldn't try to ride this thing daily on the road, because now the chain came off. I put it back on, but need to see if there is an easy way...


hi, it sounds to me like the bike has been ridden hard and needs the chain replacing due to it strecthing. on the swing arm at the back is their two bolts sticking out the end of each swing arm their should be one in one side of the swing arm and one in the other side of the swing arm, this is right at the very back of the swing arm.
if you find these then these are the adjusters for the back wheel you then need to loosen the back wheel bolt but dont take it out then adjust these adjusters by the same amount do it in half a turn a time you need to do both the same else the back wheel wont be level keep tightening them in and this will then pull the wheel back and this will tighten the chain if its all ready adjusted fully then the chain is scrap and needs replacing, if you dont have adjusters then the chain needs replacing, it will keep coming off if its slack

you can cause damage to the bike if the chain comes off whilst riding at speed so it may be best to get the chain before you use the bike



Aug 15, 2010 | 2004 Suzuki DR 200 SE

1 Answer

Chain broke and the new one wont quite fit how do i adjust the back wheel to make it fit, do I have to loosen the big lug b4 adjusting the screws


The large axle bolt holds the wheel in place. The adjusters are only used for setting the position of the wheel , mainly for chain and sprocket alignment. First remove the cotter pin and loosen the large nut on the axle bolt. Now you can loosen the adjuster bolts and slide the wheel forward. If you have the correct length chain for the sprockets every thing should fit perfectly. When you unhook the old master link do not remove the chain. Hook the new chain to the old chain using the old master link ( do not lock it on) just use it to pull the chain around the front sprocket. This will save you having to take off the front sprocket cover. I usually find it helpful to count the links on the old chain and lay the chains side by side to make sure the new chain does not get cut too short. If the chain is too short , you may have to get another master link and add some chain back in to get the correct length. Hope this helps.

Jul 07, 2010 | Honda CB 100 Motorcycles

3 Answers

1982 Suzuki GS650G timing chain install


it is possible to unlink the timing chain. I dont really recommend it, but I have done it before with no problems. if you can get ahold of a small chain breaker you can use that to press one of the pins out of the chain. you may be able to find one at a hardware store. then, use the same breaker to press the pin back into the chain. you MUST be sure that it fits tightly though, so the pin doesnt try to back out later down the road. this is what I did...for a loose fitting pin, I used a hammer with a punch to "mushroom" the ends of the pin so it cant back out. I had a friend hold the metal end of a small sedge hammer against the chain, while I used the punch and hammer on the other end, then we switched sides. Im not too familiar with your engine, but in general, you dont have to remove the crank to replace the timing chain. usually, just removing the clutch basket gives you enough access to replace it. on certain models though, the cases may be in the way, and removing the crank may be necessary. but before you break the chain or pull the crank, check to see if its possible to install a chain by just removing the clutch basket, and if necessary, the gears on the end of the crank.

Sep 03, 2009 | 1982 Suzuki GS 650 GT

1 Answer

How do you adjust the tension on the timing chain for a honda Xl185S?


Hi blazinj
To adjust your cam chain.if you remove the small bolt in the top of the tensioner lock nut there is a 3mm thread in the adjuster rod.get your self a long 3mm screw or possibly a spoke (i use a tail lamp screw)thread it into the adjuster. Start the motor and with it idling undo the lock bolt(14mm head) and pull up on the screw just enough to get rid of the rattle. Dont overdo it. Then tighten down the locker. remove the screw, and refit the cover. Done. Dont forget to rate me for the advice. Cheers
regards robotek

Jul 14, 2009 | 1983 Honda XL 125 R

2 Answers

Yamaha warrior chain.


HELLO; Heres all you should have to do this,set your quad up on a atv jack or on a milk cartoon.Loosen the four bolts that hold the rear bearing carrior and back off your adjusters then push the carrier forward till it stops,relay your chain and adjust it leaveing a little slack, tighten your mounting bolts then, something I do, spin the rear tires to see if the slack is right if not loosen the bolts and proceed again with the proceedure turning out the adjusters a little more look at the chain as you dothis and you will see the slack in the chain on the top. GOOD LUCK.

Jun 25, 2009 | 2003 Yamaha YZ 250

2 Answers

Wierd noise coming from clutch/tranny when


Does the noise sound like a whining noise or goes up and down in tone when you reve the bike in nutral? If it does the primarly drive chain needs to be adjusted. Under the bike you will see a bolt with a slot on the end of it and a nut around the bolt. This is the bolt for the chain tightner or nylon adjuster. On the same side of the bike you will see a small cover about couple of inches long with two screws in it holding the cover on. This is the primary drive chain inspection hole. You need to remove the cover and with a good flash light you will see a chain. Make sure the bike is shut off, keys removed and properly secured so it wont move. I recommend a small screwdriver to stick in there to see if you can move the chain up and down. If you can move the chain up and down more than 3/8 of inch it needs to be adjusted by turning the slotted screw clock wise a quarter of a turn. Check the chain after you made the quarter turn for starters and see if the drive chain tighten up. It should have tighten up. Keep turning the screw the same way until the primary drive chain has about 3/8 slack in it. Once again do not tighten the chain so you cant move it. The chain has to have some slack in it or it will or you will damage other components. You may also want to call the harly davidson dealer and give them the model of your bike and they should tell you the adjustment range. I run mine at 3/8 and have no problems. Also have you ever changed the transmission fluid? That would not hurt as well after you have done the above. Before you do the above chain adjustment, you will need to run the bike for a few minutes to operating temparature before the adjustment to allow for expansion.

Once you have made the adjustment, you will haft to place a screw driver in the slotted end of the bolt and use a good oepn end metric wrecnh to tighten the nut. Becareful not to over tighten the nut or it will casue stripping of the threads. Then replcae the chain cover and make sure the gasket looks ok before assemblying it. Its a good idea to pick up this gasket for a few bucks as you have about a 50/50 chance it will leak a little if you use the old one. Someone always asks me how tight do I tighten the bolts or screws. I simply say to them try and remember what it felt like when you had to loosen them. apply the same force to tighten them.

Jun 24, 2009 | 2003 Harley Davidson FXSTS Springer...

2 Answers

I have a 1994 Yamaha Virago 535cc. I want to know


There is no adjustment, it has automatic cam chain tensioners. If it is making cam chain noise, it could be right between ratchet steps and getting ready to click up to the next step.

Jun 10, 2009 | 1994 Yamaha XV 535 Virago DX

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