HELP !!! stripped threads

[bsman]

i have an 04 KLR 650, both cam cover right side bolts are stripped out.. tried JB weld twice but it does not seem to be able to grab the aluminum.. do they make a HELICOIL that size ?? any other cures like larger bolt ??? thanls in advance ....

 

[kawi_klr]

helicoils

helicoils

they do make helicoils in that size... very easy to install if your handy... just make sure you run the drill bit and the tap in straight... other wise you WILL break the tap and then your totally F+@#ed. after you wind the helicoil into place use a punch that fits in the hole and tap out the wire guide.. and away you go.. the instructions are also on the box to make ease of installation good luck to ya

 

[Sparkle]

The Helicoil would make the best repair providing stronger threads than stock. Rethreading to a larger size is an option too but no matter how you do it you'll have to cut new threads in the alloy. Like kawi_klr says make sure the tap is started perfectly straight...once you have it started straight, thread it in a turn and then turn it back a half-turn to clear the chips. Every couple of turns unthread the tap and clean out the hole with a Q-tip with a blob of heavy grease to remove the chips. Make sure the hole stays clear of chips and when the tap approaches bottom be careful you don't bottom out and tear the new thread. A little WD40 or "Easy Tap fluid" in the hole as you go will help a lot...keep it wet.

Sparkle

 

[Erronous Monk]

The number one reason these bolt holes strip-out is the use of a torque wrench. Torque numbers listed in manuals is always for dry bolts and holes. The valve cover bolts and holes were only ever dry, in the factory. These bolts are a shoulder lock, and over tightening does nothing to help the gasket seal.
It is a lot of fiddle work to use a different bolt. Go the coil route so that you can keep the factory shank length.

 

[bsman]

thanks to all of you.. bike is going back together as we speak, and i did go with the coils
thanks again