I recently got myself a new 2026 390 adventure r and love the bike so far!
For added protection of the light I bought the headlight protector from the powerparts catalogue.
Yesterday after trying some jumps I realised that the bolt holding the plastic plate in place just broke off (images attached).
And now I‘m facing two problems:
1. is it safe to remove the bolt? I don‘t want to invest in a new headlight 😅
2. how will I get a replacement bolt without having to rebuy the protector thing?
My KTM Dealer is a bit of a pain to work with if you‘re not planning on buying a superduke or supermoto from him so that‘s not my favorite option tbh.
#1, do not use a screw extractor, the soft aluminum will expand and just get locked in the threads.
Use left handed drill bits, a center punch to get started, and progressively larger bits. The aluminum will drill out easily. After you’ve gotten most of it out, use a thread tap set. Those screws are probably M5x0.8 — the thread tap will easily cut the aluminum out, but be sure to go 1/2 turn in, 1/4 turn out as you work it in.
You can order a similar piece of hardware from McMaster Carr, an Aluminum Threaded Hex Standoff. I’d suggest you get two, and completely replace the OEM hardware as the sizes won’t be identical.
This. Take your time. Not the end of the world. Regarding your second question, I wouldn't get a replacement stand off. Seems like a disappointing design that couldn't handle the stress and sheared at the weakest point. Good for coffee; bad for dirt.
This is what you need. It saved my a55 when I broke my oil drain plug and had to extract it. It was a piece of cake.
Look up YouTube video on how to use it. May need a fine drill bit to poke a tiny anchor hole in the center first.
A 12 year old with 4 KTM’s ….3 Ducatis …3 Hondas and a HOG ….…great bike…shity reliability … you must be one of those guys that spends a lot of money and tries to convince people that it was worth it lol… Not me… I spent lots of money and then tell people exactly what’s going on
The quality could be better while the price could be higher too and there aren’t any real road legal alternatives on the market atm in my opinion🤷🏼♂️
Btw flexing things you own is also something 12 year olds would do so I might be onto something
I just figured it out… You have a KTM and it broke lol and you are extremely butt hurt and anybody that talks shit about KTM’s is a 12 year-old lol! How about this… Try not to be so angry… Go buy a Honda lol
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u/reddisaurus 1d ago
I just had this happen to me!
#1, do not use a screw extractor, the soft aluminum will expand and just get locked in the threads.
Use left handed drill bits, a center punch to get started, and progressively larger bits. The aluminum will drill out easily. After you’ve gotten most of it out, use a thread tap set. Those screws are probably M5x0.8 — the thread tap will easily cut the aluminum out, but be sure to go 1/2 turn in, 1/4 turn out as you work it in.
You can order a similar piece of hardware from McMaster Carr, an Aluminum Threaded Hex Standoff. I’d suggest you get two, and completely replace the OEM hardware as the sizes won’t be identical.