Sheared off bolts and the right HeliCoil

[doctorgonzo]

First, 1981 GS1000GX

Ok, getting to Phase 2 repairs now. Two of the bolts for my cylinder head cover are sheared off. The schematic says the bolt is 6 X 35 and if I read my service manual tables correctly it's a 1.0 pitch, so I want the Helicoil M6 X 1.0 for that right... Also, two header bolts are sheared off. The best I can tell these are M10 X 1.5. I want to order the kits (found them $19.99 each everything included even the drill bit) ASAP, but has anybody had to tap these holes before? Just be great to confirm I have the sizes right.

[doctorgonzo]

I emailed the owner of Stainless cycles where I got my bolt kits. Hopefully he'll reply. I'll let you know if he does. In the meantime, if anybody else has tapped these, let me know.

[Ed Vrolijk]

Hi there,
Normaly when you buy a Helicoil set the tap should be included.
Good luck with it.
Ed

[psyguy]

First, 1981 GS1000GX

Ok, getting to Phase 2 repairs now. Two of the bolts for my cylinder head cover are sheared off. The schematic says the bolt is 6 X 35 and if I read my service manual tables correctly it's a 1.0 pitch, so I want the Helicoil M6 X 1.0 for that right... Also, two header bolts are sheared off. The best I can tell these are M10 X 1.5. I want to order the kits (found them $19.99 each everything included even the drill bit) ASAP, but has anybody had to tap these holes before? Just be great to confirm I have the sizes right.

yup, lots of them...

make sure you get whats known as the "2D" heli-coils, they are appropriate for aluminium applications, the other sizes may not hold as well
id double check for the exhaust bolts, from memory they are M10x1.25

.

[greg78gs750]

head cover bolts are 6x1. have fun....put some rags in there to get any metal bits. drill straight.

[argonsagas]

head cover bolts are 6x1. have fun....put some rags in there to get any metal bits. drill straight.

This is a VERY good idea.

It might also help to use some grease on the rag, to give the bits something to adhere to.

[chuckycheese]

Head

As Greg says, your valve cover bolts are 6mm and 1.0 pitch. I'm pretty sure that your header bolts are 8mm...but I'm not positive.

[Steve]

I don't think that the header bolts would be much different between an 850 and an 1100, so I checked on a spare head that I have here.

The valve cover bolts are 6 x 1.0 mm

The header bolts are 8 x 1.25 mm.

.

[salty_monk]

8 x 1.25 on my 1000's too...

[doctorgonzo]

Awesome, thank you guys!
Gonna order the kits tonight. Valve adjustment is next and should get those two bolts drilled out while I am at it (also replacing with machined stainless steel from stainless cycle). Bike is running the best yet, scary powerful when you hit about 5000 or 6000 RPM. Idle still wanders a bit, and major plug sooting has become very minor. I have a carbtune on the way also, but per recommendations here, valves first. Getting a pretty good raise in a couple weeks and celebration is a V&H 4 into 1.

[psyguy]

Gonna order the kits tonight

could you please post the link of the place you re buying helicoil kits from, sounds like a good price

in our lil place down here they want like us$70+ for a kit

.

[Greg O.]

If the bolts are broken off close to the surface, a person can usually weld a nut on the broken bolt. This gives you something to get ahold of, and it warms the bolt so it will help loosen the bolt. It may take several nuts welded on before it will come out, and sometimes it will come out first time. I have used this on aluminum castings, steel, and cast iron. Works great with aluminum because it expands to much.

I hate drilling and tapping in aluminum, because the bit likes to wander to the soft aluminum. YOu have to be dead on center when drilling out the broken bolt.

Greg

[doctorgonzo]

Valve cover is sheared below the hole or even for sure. The headers I'll have to pull them to know I think.

[doctorgonzo]

could you please post the link of the place you re buying helicoil kits from, sounds like a good price

in our lil place down here they want like us$70+ for a kit

.

Amazon.com.

[doctorgonzo]

Unless I screwed it up, I just ordered the Helicoil 5546-6 Thread Repair Kit M6 x 1.0 from restockit.com (via Amazon) for about 28 bucks shipping and all. Drill bit, tap, either 6 or 12 coils can't remember.