ah the struggles of a free dirtybike

[veryrigged]

Hey gang, this'll be my first thread here, and the sole reason for making this account is to ask for support about my baja dr125. My biggest problem cause here is my faulty torque wrench, but on top of that, I snapped a head bolt... it can probably be imagined what words were said when the torque wrench gave and slammed my hand into a sharp point on the bike.... (yaaaay) So at this point, Im looking for repair options. Running the bike on just the 3 bolts is likely not an option, considering the head could be warped, Ive thought about taking the other end of the bolt out, and cutting the snapped parts, and welding it shorter, but Im unsure of how much stress that joint will be able to take. I called up baja, and they gave me a number to call, but Im not liking the odds of it working. Should that fail, what are my options?



Thanks for readin, hopefully someone here has some insight about this predicament

[JerryHawk250]

Welcome Aboard! I'm assuming this is a horizontal 125cc engine. A quick search on ebay and here's what i found. Just verify the length and stud size. https://www.ebay.com/i/114093840489?...BoC2dgQAvD_BwE

[veryrigged]

Thanks for the response broskii, I took out the bolt, and measuring it looks to be around 4 15/16 (126mm), but thats likely slightly stretched out due to the breaking area, so maybe more like 120mm. Width is probably 11-12mm, But I cant find anything with that size on ebay, is there possibly anything else out there I can look for?

[JerryHawk250]

Can you post pictures of the engine? Also post a picture of the engine number.

[veryrigged]

[JerryHawk250]

Okay, that a Honda CG 125 clone. The stud will be 8mm x 122mm. I'll see what i can find.

[JerryHawk250]

these are the Honda part numbers i found. 90034-397-101 and 90032-377-010. I would contact this seller on Ebay and verify the dimensions. https://www.ebay.com/itm/HONDA-CB400...wAAOSwEaBZ~W7F

[veryrigged]

Thanks for sharing that, I did some more looking based on the part number for that, and found these, https://www.ebay.co.uk/itm/223328530089. Theyre still out of country, but they ship a little bit faster, and cheaper, which is nice. What are your thoughts?

[franque]

I'd go with Jerry's option... Just verify the sizing. In all honesty, you might be able to go to a Grainger and get what you need.

[veryrigged]

I have another idea. It almost seems like there would be enough room to use a coupler, what are y'alls thoughts on that? (if this were a nice bike, I'd always prefer always to get correct parts for it, but since this is my experimental bike, I wouldn't mind taking a few shortcuts)

[JerryHawk250]

The hole that that stud passes through is an oil passage so you don't want to restrict that in any way. You could possibly use a harden all thread rod but would need to machine down the center portion. Or swap one of the other studs to that position and use the all thread rod there.

[Bruces]

Just buy a proper one instead a screwing around ,if it fails it will cost a lot more than the original stud .

[JerryHawk250]

Originally Posted by Bruces

Just buy a proper one instead a screwing around ,if it fails it will cost a lot more than the original stud .

I totally agree. But i've seen myself do some jerry rigging on old stuff that i didn't want to sink money into. If it crapped out then it became recycle scrap. lol

[veryrigged]

Thanks for stayin tuned gents. I went ahead and decided to weld it, it aint a great looking weld, but functional enough. Should this fail, I'll just do the 212 swap all my buddies keep telling me about. This motor is pretty worthless, so I really dont feel like sinking money into it. I put it all back together, torqued 3 of those down to 20ftlbs or so, and the broken one to probably 10ftlbs. If it breaks, oh well. Ill probably just get allthread next time

[franque]

It won't be a straightforward swap to a 212, that's a completely different engine family.