Cbr6 spat a plug

[kramdra]

Testing begins. Took me about 20 attempts to get one in properly seated. I'd forgot, it is essential to release the tension every half turn or so, but still a pain and the last turn never wants to seat. Also helps if the insert is pre-stretched similar to the pitch, which these are not..

https://i.postimg.cc/cCrxTSkj/IMG-20200503-180926.jpg

I had an old insert test that jumped a thread. Re tap it.
https://i.postimg.cc/6pyZT8Vs/IMG-20200503-181141.jpg

It cut. A real pain to get started and may be a risk of it pushing insert through. Tbis one did not, just lo ger than the test thread..

https://i.postimg.cc/4xWmvs56/IMG-20200503-182006.jpg

Success. Where the thread had jumped, it cut through the plug side, remains a single peice and plugs go in easy.

Running the tap has a risk but I think it will sort it properly.

[Riejufixing]

What is your actual plan?

[kramdra]

Found bore camera I will have a look tomorrow then I'll make up a tap extension and retap all 4 plug holes and refit with the better plugs.

Then I can resume fixing the real problem. Ive ripped the bank angle sensor off, Im going to add a bypass switch on that, which I hope I dont need. And look at the throttle bodies, they are a mess.
If I can get her to fire up, I'll order another full fork rebuild kit, air filter, maybe a fairing kit, and try to get it all done before the lock down ends!

[Riejufixing]

How are you going to deal with the hole with the shagged helicoil in it?

[kramdra]

Put camera down it, couldnt see anything wrong with the thread. Tonne of dirt all around the plug hole.. Piston is noticably shit, too. Must be some dirt or swarf, bouncing around for the last 35 thousand miles but nothing to suggest she wont do another 35, I assume what ever was in there has either melted away or escaped.

I did not make tap extension yet, Ill try tapping tomorrow.

[kramdra]

Made the extended tap holder. Ground a flat on the tap, grub screw to lock it. Do not want falling down the bore !

https://i.postimg.cc/T2y7JNDX/IMG-20200505-153559.jpg

[mentalboy]

[kramdra]

Drill was for the hole and the picture.. and it was shit work, too big. Attempt two.. I filed a 7mm hex to drive it with mini ratchet.

https://i.postimg.cc/XvCKh9Jq/IMG-20200507-180930.jpg

I spent most afternoon today retapping one hole, very careful, checking with cam every half turn. While it worked, the m3 thread for grubscrew eventually fucked itself just as it was about done. I didnt want to risk the tap or screw falling so stopped, pretty sure I was at the bottom. Future tools will be en19t or en16t.

The other threads look good (seats look like shit) so I didnt bother retapping. Fit the new plugs, counted the turns and done up tight. If there is a next time (on any bike!), I will blast every pot with air to remove the dirt before removing plugs.