Stripped lower slave cylinder bolt...

[Artful]

Finally got around to replacing the shaft o-rings on my clutch pushrod and came across the unpleasant discovery that my lower slave cylinder bolt hole is stripped. What would you folks recommend? Helicoil? Tap in a larger diameter? New case cover...?

Trying not to pull the cover if I don't have to but if it comes to that I can.

[deanknight636]

just tapping it out to the next larger diameter is usually my choice, and usually the easiest and cheapest method.

[ducpainter]

IIRC that is a 6mm screw. I don't know if there's room for an 8mm screw head in the slot on the slave.

A helicoil will most likely back out the next time you have to remove the slave, but I think for that application I'd try it before using a keensert which is a much netter repair.

A little red loctite on the helicoil on installation and some oil on the screw would go a long way to preventing the backing out.

[deanknight636]

you can drill out the hole on the slave to an 8...... just a thought

[Artful]

So... drilling and tapping for either a larger bolt or a helicoil, should I be concerned about the shavings that will end up dropping into the case? I remember the size of some of the pieces of metal in the oil at the 600 mile service... I intend on putting a magnet on the drill regardless but that won't catch everything.

[ducpainter]

So... drilling and tapping for either a larger bolt or a helicoil, should I be concerned about the shavings that will end up dropping into the case? I remember the size of some of the pieces of metal in the oil at the 600 mile service... I intend on putting a magnet on the drill regardless but that won't catch everything.

I don't think a magnet will catch any aluminum...

unless you have a special magnet. 

try grease on the drill and tap.

[deanknight636]

dril the slave while it is off of the bike as for the side casing, well you can either try the grease or you can change the oil afterwards.   when you tap it if you just turn the tap in a few turns then back it out a couple you will dump out the shavings from the case.  just keep doing that untill its tapped properly and you should be good

[Artful]

I don't think a magnet will catch any aluminum...

unless you have a special magnet. 

try grease on the drill and tap.

Lol I do, works great on non-ferrous metals...

Bear with me, all my drill out work has been performed on old VWs and Harleys. I'm not used to this thing called "progress".

[Speeddog]

Whatever you do, keep it a 6mm bolt.

If you go up to an 8, then you've got a bastard combination.
Makes future part replacement a hassle.

I like Time-Serts.

[Artful]

Went with a helicoil, other than the setting tool getting stuck and taking a little persuasion to remove, all went well. I'm in the middle of replacing my rear sprocket and chain so can't say for sure I have cured my oil leak from the slave but it's a start. All this for an o-ring replacement lol.