Author Topic: IT200 engine bolt size, lengths, and quantity.  (Read 3498 times)

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Offline Zrt1200

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IT200 engine bolt size, lengths, and quantity.
« on: May 28, 2014, 05:24:14 AM »
For any one needing to replace any engine bolts or want to get a set of stainless steel allen wrench ones here is the size and lengths with quantity you will need. I also replace my stator bolts with stainless steel socket head button head which use a allen wrench. Al



Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1

Offline Martin I Henry

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #1 on: May 28, 2014, 06:10:38 AM »
Cheers, Al.

Might change my bolts when I get the time.

Dave R.

Offline Zrt1200

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #2 on: May 28, 2014, 06:23:04 AM »
I am doing it slowly Dave. Steel and Aluminum are natural enemy's and like to corrode together so I swap them out when I take them out. The same goes for bolts like the seat, Side panels, muffler, etc in the steel frame. I swap them out with Stainless ones. I had way to many broken steel bolts on a Suzuki Quad to deal with steel bolts in aluminum any more.  May be it is just Suzuki's that have that problem ;D
Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1

Offline fred99999au

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #3 on: May 28, 2014, 07:36:35 AM »
Thanks Al. Hopefully that kit you referred to on fleabay will contain exactly this.

Offline Zrt1200

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #4 on: May 28, 2014, 08:53:05 AM »
Thanks Al. Hopefully that kit you referred to on fleabay will contain exactly this.

Your welcome. If you are going to buy the kit ask them now that way you know what is in it.  ;)
Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1

Offline fred99999au

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #5 on: May 28, 2014, 10:46:47 AM »
too late, but I will compare it against your list to see what is missing.

Offline 2fITy.J

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #6 on: May 28, 2014, 04:06:09 PM »
The Yammy part numbers give the thread size and bolt length so it should be easy to cross reference them.

Haven't had issues with any Suzi bolts as yet....not since the early 70's anyway!

Only bolts I seem to have issues with is someone else's bike that I have gotten.....cheap!



Cheers,
Chris.
A bike in the bush is worth two in the shed!

BMW-BSA-Ducati-Honda-Kawasaki-Lambretta-Matchless-Norton-Suzuki-Triumph-Vespa-Yamaha.

Dirty Dozen '13 DR650SE - '90 DR650RS - '82 IT465J - '82 IT250J - '80 GT80G - '77 A100B - '76 DT100C - '76 TC125 - '75 TM75 - '73 MX80 -       '73 TC100K - '69 TC120-1

Offline maxbo

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #7 on: May 28, 2014, 08:32:35 PM »
Great post Al.  Would be good to get all the useful stuff like this together in one section ie brg no's for g'box, wheels, seal sizes etc  I know a lot of this is on the forum but you never seem to able to find it when you need it (Murphy's Law)
Cheers Max

Offline Zrt1200

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #8 on: May 28, 2014, 10:13:55 PM »
Great post Al.  Would be good to get all the useful stuff like this together in one section ie brg no's for g'box, wheels, seal sizes etc  I know a lot of this is on the forum but you never seem to able to find it when you need it (Murphy's Law)
Cheers Max

Thanks Max. Yes I agree with you. May be we need to mention it to Jock to put this post and the non OEM bearings into one folder. It would save space and clump it all into one place so it would be easy to find. I know I have a post on here with the sleeve part numbers some where on here as well. Stuff like that all in one folder is a good idea. AL
Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1

Offline 2fITy.J

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #9 on: May 28, 2014, 10:19:48 PM »
Similar things are in place at the moment but sometimes guys get excited (or angry, frustrated etc) and start a thread to get quick responses I guess. There are quite a few threads covering things like jet spec's, tips for rebuild pitfalls, cross matching parts, frame/engine numbers, other sources(vehicles) for same size bolts etc.



Cheers,
Chris.
A bike in the bush is worth two in the shed!

BMW-BSA-Ducati-Honda-Kawasaki-Lambretta-Matchless-Norton-Suzuki-Triumph-Vespa-Yamaha.

Dirty Dozen '13 DR650SE - '90 DR650RS - '82 IT465J - '82 IT250J - '80 GT80G - '77 A100B - '76 DT100C - '76 TC125 - '75 TM75 - '73 MX80 -       '73 TC100K - '69 TC120-1

Offline Martin I Henry

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #10 on: May 29, 2014, 05:34:58 AM »

Stainless bolts are good for producing fake ' works ' looking items.

Take one boring old Low Head M6 stainless bolt :


Quick spin in the lathe :


Or as used on the Yamaha YZM500:


Cheers,

Dave R.


Offline sweede490

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #11 on: May 29, 2014, 08:32:23 AM »
Just s tip ..

   Always use copper coat or res-Q steel on the threads
   Of stainless bolts being used with aluminium or
   Magnesium , or you will have corrosion issues

     One of first things you learn when building alloy boats





     Muzz

     
Jack Burn Yamaha   WR500   IT490L  WR450   Desert sled

Offline Zrt1200

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #12 on: May 29, 2014, 11:46:49 AM »
Just s tip ..

   Always use copper coat or res-Q steel on the threads
   Of stainless bolts being used with aluminium or
   Magnesium , or you will have corrosion issues

     One of first things you learn when building alloy boats





     Muzz

     

Muzz, I work in a mold shop and seen first hand the difference from steel bolts VS Stainless steel bolts in aluminum after 10 years of service. The steel bolts we have to drill every one out as they just snap off from all the corrosion. There are like part of the aluminum. The stainless bolts come out with out breaking at all. Al
Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1

Offline 2fITy.J

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #13 on: May 29, 2014, 03:48:06 PM »
I knew there was something that needed to be applied to stop the "welding" by corrosion....thanks Muzz.





Cheers,
Chris.
A bike in the bush is worth two in the shed!

BMW-BSA-Ducati-Honda-Kawasaki-Lambretta-Matchless-Norton-Suzuki-Triumph-Vespa-Yamaha.

Dirty Dozen '13 DR650SE - '90 DR650RS - '82 IT465J - '82 IT250J - '80 GT80G - '77 A100B - '76 DT100C - '76 TC125 - '75 TM75 - '73 MX80 -       '73 TC100K - '69 TC120-1

Offline stainlesscycle2

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #14 on: June 12, 2014, 11:37:11 AM »
Muzz, I work in a mold shop and seen first hand the difference from steel bolts VS Stainless steel bolts in aluminum after 10 years of service. The steel bolts we have to drill every one out as they just snap off from all the corrosion. There are like part of the aluminum. The stainless bolts come out with out breaking at all. Al

as long as you are not in a saltwater environment, there should be no issues with stainless in aluminum.   anti seize is recommended of course...




Offline Zrt1200

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Re: IT200 engine bolt size, lengths, and quantity.
« Reply #15 on: July 17, 2017, 10:55:08 PM »
Here is the original pic I had posted Photobucket.
Current bikes, (82) IT465J, (85) IT200N, (05) GasGas 200, (11) DRZ400S, More photos can be found at.....

http://s582.photobucket.com/user/Zrt1107/library/dirt%20bikes?sort=3&page=1