Stripped Thread Fix

[Hank025]

I stripped the "long bolt" thread for the clutch cover. I left it hanging out in this picture...


How do I fix this? The thread is so far down into the engine case I don't think TimeSerts will work unless I remove the entire clutch assembly? Plus I obviously don't have the mechanical skills to drill into my engine case...

Has anyone tried the Loctite Epoxy? http://www.amazon.com/CRL-Loctite--Thread-Stripped-Thread/dp/B001Q5GOFS/ref=sr_1_1?ie=UTF8&qid=1315878136&sr=8-1

When I got the bolt out there was two small shavings on the bolt. Honestly, I barley turned the allen wrench with my hand when it snapped.

I've done the search and was hoping there was an alternate solution to drilling...but if there isn't, does anyone know of anybody in Philadelphia that can do this? Do I need to fix it?

[teddy037.3]

if it only stripped out at the very top of the thd you might be able to dress it with a tap...

never had a dry clutch bike, so I have no idea what needs to be removed to reach in there...

[Speeddog]

Yes, you would need to remove the clutch and sidecover to repair the thread.

There are long taps available, they're called extension taps or pulley taps.
The M6x1 size is available in an extension tap, 82mm overall length.
I don't think that's long enough to do the job with the cover on.

I've seen quite a few bikes with a long bolt or two missing or loose on the clutch sidecover, and they weren't leaking.
Not the best situation to be sure, but there you go.

[monsta]

the thread maybe deeper in the hole than the bolt that stripped it..  you might be able to get a 5mm longer bolt to replace the existing one and just 'nip' it up...

but yeah, best fix is to take the clutch off...

[Hank025]

Wow, so my understanding right now is:
In order to get to the stripped part of the thread I would pretty much have to remove the entire right side of my engine case?

Sounds much bigger of a job than I can take on. So much for "bolt on" parts...

If so... will they take take the clutch side of the engine case apart during my Valve Clearance scheduled maintenance? If so, I will just wait to take it in for service before I have this thread repaired. Can my local Duc shop re-thread the hole?

[Speeddog]

Wow, so my understanding right now is:
In order to get to the stripped part of the thread I would pretty much have to remove the entire right side of my engine case?

Yes.

Sounds much bigger of a job than I can take on. So much for "bolt on" parts...

If so... will they take take the clutch side of the engine case apart during my Valve Clearance scheduled maintenance? If so, I will just wait to take it in for service before I have this thread repaired. Can my local Duc shop re-thread the hole?

Taking those parts off isn't included in a valve clearance check/adjust.

They should be able to repair the hole.

Again, I've seen several bikes running without that bolt, and not leak.

And as Monsta said, you may be able to get a longer bolt to grab the threads that are left.
See if you can find one 10mm longer and get it to thread in.
Be prepared to use some washers under the head, as there might not be quite enough threads.

I'm pretty sure the next bolt down is a bit longer, as there's a locating bushing on that hole.