| Author | Message | ||
     Cereal |
Thought I'd post here too. I want to helicoil it because the damn thing stripped too easy the first time, and I don't want to spend the money on a new primary cover just to strip it again. I tried different nuts on the clutch cable and nothing worked. Bottom line question: what size is the hole? http://www.badweatherbikers.com/buell/messages/327 77/302032.html?1188152424 | ||
| Jackbequick |
Any one have a clutch cable laying around? I seem to think it was 3/8-24 thread (same thread as a 3/8" Fine or SAE bolt. If some one can compare a bolt to a cable end, it would confirm it. The torque spec on that very fragile aluminum cable end is expressed stupidly in the service manual. It has it as 3 foot pounds or something like that (not 36 inch pounds). But almost any measurable turning force can be too much on that fragile cable end. But in any case, what works is to screw the cable in by hand until the O-ring is slightly deformed and then quit. The normal curve in the cable will keep it from unscrewing itself. Jack | ||
| Stalker |
its a 5/16 x 24 | ||
| Cereal |
Nope. 5/16 x 24 won't go past the first 2 threads. I went to Home Depot and finally found the correct size, M8 x 1.0 (fine). Now I can't find the Helicoil kit, only the coils. The only thread repair kit I can find is made by Recoil. It's the same thing as Helicoil, just 3 times as expensive. Oh well, still a lot cheaper than a new case. And I won't have to worry about it stripping again! | ||
| Al_lighton |
Probably more than you want to pay, but keenserts are better than helicoils: http://www.mcmaster.com/param/asp/psearch2.asp?req Typ=parametric&act=psearch&FAM=insertsformetals&FT _104=141&FT_163=4576&FT_161=10907&FT_1419=60358&FT _147=60652&FT_137=60708&FT_2595=113377&FT_2596=113 378&FT_2604=113611&FT_2605=113643&FT_355=113645&FT _869=128773&FT_4551=200624&FT_4548=200635&FT_4552= 200647&FT_3174=200826 But if you want to spend a lot less and get helicoils: http://www.mcmaster.com/param/asp/PSearch2.asp?req Typ=parametric&act=psearch&FAM=helicalins&FT_161=1 0907&FT_2678=116651&FT_163=4576&session=helicalins;161=10907;2678=116651;163=4576&sesnextrep=2310187 2397964&ScreenWidth=1152&McMMainWidth=890 I love mcmaster carr. Al | ||
| Al_lighton |
Oh yea, Jack is sooooo right. The other mistake people make is to try to thread that cable threaded end in or out while the clutch cable is still installed on the bike. That just puts lots of reverse bending in the threaded part and guarantees that it will break. WAAAAY too many people buy one and then buy another one. If it is handled with care per what Jack wrote, it doesn't have to be that way. Me, I made the problem go away with a hydraulic clutch actuator setup. They have their own failure modes, but I like 'em better. AL | ||
| Cereal |
Damn. I wish I would have seed your email earlier. That site never showed up in my extensive google searching. I already ordered the Recoil kit for twice the price. | ||
| Al_lighton |
IT IS NOT AN 8mm x 1mm thread!!! That answer just bugged me, so I pulled a cable from stock and I just put one up against my tap set, and the cable end will not interlock with the 1mm thread pitch. I have an american tap set, and it mates perfectly with a 5/16-24 tap. I hope your thread insert kit is returnable and that you haven't done the work yet. Al | ||
| Cereal |
Mine must be different, because I tried many different sizes, including 5/16-24, and they did not fit past the first two threads. I tried the M8x1.0, and it slid right on.  | ||
| Cereal |
Found that the M8x1.0 does thread, but 5/16x24 threads a bit smoother. I guess the Home Depot I was at had the wrong nuts in the 5/16 bin. Thanks Al for the heads up! | ||
| Jackbequick |
Bolt = 8mm = 0.3149597" Bold = 5/16" = 0.3125" Thread pitch of 1mm = 25.4 threads per inch. Those are close enough that with the variations in sizes due to tolerances (largest nut, smallest bolt, etc.) you can get them to fit together for a number of threads. You could save the primary cover by making a threaded insert with a larger external thread and a 5/16-24 internal thread. That insert could be made by finding someone with a lathe that can take 7/16-20 bolt or 1/2-20 bolt and drill and tap a 5/16-24 hole through it. And while he has it in the lathe, have him thin the head down to 3/32-1/8" or so. And have him part the excess length off so there is only one or two more threads morse than will span the material of the case. Then drill and tap the case for the 1/2-20 or 7/16-20 bolt and put the bolt in with red Loctite. Tighten that bolt to like 3 inch pounds or so because there are only a few threads here and the cases are made from crappy and granular grade of cast aluminum. Good luck! Jack (who does not have a lathe any more...) | ||
| Stalker |
Nope. 5/16 x 24 won't go past the first 2 threads who would trust a machinist on a thread size any way? what is your time worth? what is a machinist's time worth? i would just suggest getting a new primary case for the $175 and not worry about it. not trying to be a smarta$$ but i have access to all sorts of tool-room machines and know how to use it (after all that is what i do for a living)and i would charge more than $175 for all that messing around. | ||
| Cereal |
I don't know what you two are talking about. You take a $30 helicoil kit, install the coil into the primary using the included tools, then screw in the clutch cable with a little bit of antiseize. Done. Total cost: $30. Total time: about 20 minutes. | ||
| Al_lighton |
I'm with you, Rob. Seems easy enough to me, and you have nothing to lose in trying it other than the $30/20 minutes. I'd probably coat the helicoil with JB weld, and thread a screw coated in vaseline in it while the JB weld dried, but that's just me being overly cautious getting a liquid tight seal on the helicoil/cover fit and ensuring that it never threads out with the clutch cable. The hardest part of the job is turning the tap since you can't use a T-handle without a long extension at taht location. But I've always been able to use a 1/4" drive 12 point socket on the square end tap on such cases. Al | ||
| Cereal |
Thanks Al! I'll pick up some JB weld and give that a shot. Maybe I should also check to see if I have any vaseline left...  | ||
| Cereal |
The helicoil is in. It was very simple to install and after one quick 50 mile ride, I've detected no leaks. I will keep an eye on it for a while. |
