redoing hele-coils?

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

When I attempted the valve clearances on the Blandit I fucked up two of the eight threads on top of the valve cover. Yea, yea I know - hamfisted fuckwittery at it's finest Razz

Anyhoo, my mechanic in his wisdom hele-coiled them when he re-did the valves although he later admitted they were 'dodgy' as he had to use a slightly incorrect size. He told me to order in new parts (these things are the half circle top piece which hold the camshafts down) but after speaking to the Suzuki dealer - guess what! Yea they don't sell 'em, come with the whole lot because of tolerances etc.

I guess my question is have you ever re-done hele-coils and if so, how hard is it? Reckon I should get the garage to have a go? They mentioned they could repair them but I'm wary of spending £££'s.

Any ideas?
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

So your mechanic has lunched your head basically as he couldn't be bothered to get hold of 7mm inserts for the cam cover bolts.

I may be able to repair them, I do a fair few of these but would need to look at them first off the bike.

At the worst depending on which cam holders it is I might have some but would then need to whole head and cams to get it line bored so they fit without wearing the cams out or seizing quick time.

I wouldn't use that mechanic ever again but I would consider sueing him for the cost of a new head. In the region of £1200 not including valves, guides, seals, building, head gasket and fitting.

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

Not 100% sure I understand your post dude, although thanks for the offer.

Are these things I can unbolt and take off and get done, then reattach to bike?

Very Happy

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NSR125RR - ZXR750H1 - ZX9R E1 - GSF600S - GSF600SK3 - VFR400-NC30 - SV1000N - ST1100-R - CBR900RR-R - GSF1200SK5 - GSF600SK1 - VFR1200FA - GSXR1000K2 - ZZR1400 D8F
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Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

The guy who did it has lunched your head as he's useless. You could get some caps and then as sickpup says you'd have to send the head / cams / caps away to SEP or suchlike to get it all machined to work. You can remove the caps and get them fixed, but i'd be more inclined to fit them up the mechanics' arse.
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sickpup · Old Timer Joined: 21 Apr 2004 Karma :

On each cam there are 5 bits of Aluminium that hold the cams to the head. The top of 8 of these has an M7 thread to which the cam cover bolts onto. This is a design that is used to this day on most Suzuki sports bikes.

Your mechanic has over tightened the cam cover bolts, they only need about 10nm of torque. Then instead of fitting 7mm heli coils it sounds like he's just made a mess.

I would need to look at the caps to see exactly what he's done and how deep he's cut to decide if a repair back to 7mm is viable. If not I may be able to get some 8mm threaded caps from the states but again depends how much damage he's done to the caps.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Heres the 8mm threaded 1mm oversize cam cover bolts.

clicky

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Yeah my 'busa has 7mm caps too. I found out when I was going to mount my DTA using one of them for doing my cam timing Very Happy

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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

You take off your rocker cover and post me the cam caps and I look at them or take them to an engineering workshop.

The 8mm bolts are weaker than the 7mm ones.

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Another option you have is if you want to helicoil them out to 8mm then send me the M7 retaining bolts you have, I'll machine them out to accept M8 socket caps. Wouldn't take long and you'd have them back in 2 days.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

At the moment I'm a courier but yes I've been accused of being a mechanic and I have all my equipment and gear at home.

Couple of quid if that each cam holder. Cover the cost of me getting hold of the 7mm inserts and the postage of course.

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

G · The Voice of Reason Joined: 02 Feb 2002 Karma :

Timesert inserts are bigger than helicoils.

They also do a 'bigsert' which has oversized outer dimensions to repair inserts that have messed up.

Kits are very expensive to buy, however.

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Kris · World Chat Champion Joined: 03 Feb 2002 Karma :

Righto

I've been a proper slack monkey with regards to getting these done. In other words I left it. Now the bike needs the clearances doing and the 'bodge' is barely holding Embarassed

So, first off are the offers still available that were posted here? Razz

Cheeky I know but hey Thumbs Up

Secondly, any more ideas? I may be able to wheel the bike down to a garage who can hele-coil them 'in the frame'. Is this wise? I notice sickpup reckoned some bad things could happen if they move etc..

Anyhow, thanks for listening all.
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NSR125RR - ZXR750H1 - ZX9R E1 - GSF600S - GSF600SK3 - VFR400-NC30 - SV1000N - ST1100-R - CBR900RR-R - GSF1200SK5 - GSF600SK1 - VFR1200FA - GSXR1000K2 - ZZR1400 D8F
www.prisonplanet.com

sickpup · Old Timer Joined: 21 Apr 2004 Karma :