Problem with heat shield screws on KLR.

[VIMike]

I was taking the screws out of thelong exhaust heat shield and noticed some threads left behind in the two holes. I went to Lordco and got a 6m tap, but that isn't working andit just keeps turning butnever grabbing any threads.Have I got the wrong size tap???? Do the two holes go straight through into the exhaust pipe? Got any ideas?

VIMike

 

[Phoenix]

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Don't have a KLR, but it would be unusual for heat shield screws to go right into thepipe itself. Therefore the tapered end of the tap will not allow you to get far enough to bite. As to the right size tap, access to a gauge or dies to check the bolts would help and then you can take some of the taper off with a bench grinder to try and shallow tap the holes, failing that big hammer, vise grips, cold chisel and copius amounts of swearin' and JB Weld might work:shock:.

 

[tom thumb]

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maybe u can get a heli coil to fit in there

 

[Mr. Harrod]

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You will likely need a bottoming tap one size or so larger it you want to make this system work again. When this happened to me I got suitable studs and then brazed them into the holes. The heat shield then reattaches with lock washers and a nut on to the stud.

MH