The kickstand on the KTM EXC models is perfectly adequate to hold the bike up and do the job it was designed to do. However, if you load a KTM EXC with luggage for adventure riding, or try and pivot turn the bike on the kickstand, or use the kickstand to get on and off your bike, the kickstand has a tendency to fail.
This kickstand failure can be in the form of the kickstand bolt breaking, or the actual kickstand breaking. This is experienced by many KTM EXC owners out there.
This is the KTM EXC 500 I ride which carries a lot of luggage when heading away on multi-day adventures. I avoid using the kickstand to get on and off the bike, and also avoid pivot turning the bike on the kickstand. For me, it is the actual weight of the adventure luggage that has led to three kickstand breakages, and two kickstand bolts breakages.
Fixing a Broken Kickstand Bolt
There are a number of ways to fix a broken kickstand bolt on a KTM EXC, below is how I do it which includes removing the footpeg as this makes the process so much easier.
Broken kickstand bolt on a 2018 KTM 500 EXC-F
Centre punch the broken kickstand bolt
First, centre punch the broken bolt face. This will guide the drill bit when drilling a hole down the centre of the broken kickstand bolt.
Centre punch done
Here you can see the broken kickstand bolt has been centre punched fairly accurately in the centre
Drilling the broken kickstand bolt
Using a 2 mm drill bit, rest the bit in the centre punch mark and drill a hole approximately 20 mm deep. It is important to drill the hole on exactly the same plane as the bolt.
2 mm hole drilled
While the hole will end up being 4 mm in diameter, I find it much easier to drill a pilot hole with a 2 mm drill bit first
4 mm hole drilled
Once the 2 mm hole is drilled, switch to a 4 mm drill bit and drill a 4 mm hole in the broken bolt. Again, this should be approximately 20 mm deep
Using an Easy Out to remove the broken kickstand bolt
An Easy Out is the perfect tool for the job
Here is a link to buy the Irwin easy out bolt extractor set - very good quality
Easy Out size for kickstand bolts
The size used here is a #3 which is designed for M8 and M10 bolts and is used with a 4 mm drill bit. This is why the hole in the broken kickstand bolt was drilled to 4 mm
Easy Out setup
While it is possible to use an easy out with just an adjustable spanner, it is much more effective using T handle on an adjustable tap chuck.
A simple fixed T handle like this can be used.
Or, a socket set with a T handle and extension can be used.
This is the Teng Tools 1/4 Inch Drive Adjustable Tap Chuck which is a great product and perfect for broken bolt extraction.
Starting to remove the broken kickstand bolt
Place the Easy Out in the 4 mm hole drilled into the broken kickstand bolt. Apply firm pressure on the bolt and turn the handle counterclockwise
Broken bolt extraction
Once the broken kickstand bolt starts to move, simply keep on winding until it comes all the way out
Success! Broken kickstand bolt out
The portion of the broken kickstand bolt has been removed
Running a tap through the thread
To finish the job off, run a tap through the thread. This is to ensure that any damage to the thread that may have occurred by either the bolt snapping or the extraction process is cleaned up. With this done, the new bolt will thread in without binding. The tap for the KTM EXC is an M8 X 1.25 and the best tap to ensure as much of the thread as possible is cleaned up, is a plug tap.
Cutting lubricant
Before running the tap through the thread, liberally apply a cutting compound to both the tap and the thread
Cleaning up the thread
Run the tap through the thread until it bottoms out and then extract the tap
Broken Kickstand Bolt Removed - Job Done!
The broken kickstand bolt has been removed, the thread has been cleaned up and the bike is ready for a new kickstand bolt to bolt the kickstand back on.
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