Fork Leg pinch bolt stripped thread
 

I have just changed the tyres on my XTZ to find that the last owner had overtightened one on the front wheel pich bolts as half the thread came out with the bolt.

As a temporary fix I tapped out the hole right to the very back and have used a longer bolt which looks crap. What I would like to do is to use a helicoil or thread insert to repair this damage, has anyone else had the same problem? I have never done such a repair but obviously I would need the replacement threaded section to be at the bottom (end of the hole) past the split where the bolt tightens the clamp - hope that makes sense. I think that would mean drilling out the front section far wider than designed to gain access for the drill and tap to access the rear section. Any advice gratefully received or do I have to buy a whole fork leg bottom?

Many thanks Daveb

Dead easy to repair.

http://www.ebay.com.au/itm/Helicoil-5546-8-M8-x-1-25-Metric-Coarse-Thread-Repair-/350193430756?pt=Motors_Automotive_Tools&hash=item5 18927b0e4

I stripped and helicoiled (well, actually 'Armacoiled') both the pinch bolts on my stock forks on separate occasions in the 29,000 mile (and countless wheel removals) before I changed the forks. They're fairly soft castings.

There's no problem with going through the clearance (front) part of the hole to drill and tap for the thread insert.

Remember that tapping drills are smaller than the nominal thread size, and clearance drills are bigger, so although you will be effectively using the tapping drill for the next size thread up, it's still smaller than the clearance hole for the original size.

If I remember correctly the drill goes straight through and the tap just lightly marks the bore of the clearance hole. No issue.

what forks you got? (just being nosey :) )

http://xt660.com/showthread.php?t=17835&page=2

Post #18 onwards.

Armacoil kits are usually available at Machine Mart - if you can't wait for eBay.

This is why mine has Armacoils in.

I guessed.

Machine Mart - there to help impatient people.... I have a loyalty card!

Stripping a thread holding one of the wheels onto your everyday transport is not conducive to patience :D

Chaps thanks for all your help Daveb