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| XT660Z Mods Share views on all the mods you have done and those you intend to do |
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 25-10-12, 13:53
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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 |
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25-10-12, 14:02
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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
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Click here to join the XT Supporter's scheme Mods that I have done to my XTX's My 04 XTX Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil / [ My 07 XTX Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator / My 09 XTX 59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details Now ride a 2018 MT09SP ABS + TCS My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946 
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25-10-12, 14:05
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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.
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I spent a lot of money on travel and racing motorcycles - the rest I just squandered. XT660Z - Commuter, Adventurer...Racer? www.dashmoto.net Other bikes >> MT-03 / CG125BR-J / ER-6F Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400 
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25-10-12, 14:12
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Quote:
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25-10-12, 14:20
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__________________
I spent a lot of money on travel and racing motorcycles - the rest I just squandered. XT660Z - Commuter, Adventurer...Racer? www.dashmoto.net Other bikes >> MT-03 / CG125BR-J / ER-6F Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400
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25-10-12, 14:28
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Armacoil kits are usually available at Machine Mart - if you can't wait for eBay.
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>-------< Never underestimate the power of stupid people in large groups. 
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25-10-12, 14:32
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Quote:
__________________
I spent a lot of money on travel and racing motorcycles - the rest I just squandered. XT660Z - Commuter, Adventurer...Racer? www.dashmoto.net Other bikes >> MT-03 / CG125BR-J / ER-6F Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400
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25-10-12, 15:04
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Quote:
Machine Mart - there to help impatient people.... I have a loyalty card!
__________________
>-------< Never underestimate the power of stupid people in large groups.
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25-10-12, 16:02
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Quote:
__________________
I spent a lot of money on travel and racing motorcycles - the rest I just squandered. XT660Z - Commuter, Adventurer...Racer? www.dashmoto.net Other bikes >> MT-03 / CG125BR-J / ER-6F Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400
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10
25-10-12, 19:45
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Chaps thanks for all your help Daveb
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