Insert Help
 

85 xt600 Kick start

Cam chain tensioner cover bolt has bad insert. Other one is good.

Looking for advice
Could I tap to next size up into the case or put insert in? Tap to M7
I don't have M6 inserts currently

Thanks

if you mean something like helicoil / keensert etc., then you must already been running out of useful space for new insert.
Or, if you mean just damaged thread in aluminum body, AND if old thread is not completely stripped than m7 should work. not sure if there's enough material for m8.
I've done one m6 to m7 and few m6 to m8 conversions on different places on engine and they all work fine for years.

Thanks

Going to pull out remainder of old insert then install M6 helicoil.
Was scared to drill a bigger hole and tap a M7

After looking at this better, there is not a lot of room to drill it out to put a M6 helicoil in there.

Anyone done this repair on the tensioner cover?

"if you mean something like helicoil / keensert etc., then you must already been running out of useful space for new insert.
Or, if you mean just damaged thread in aluminum body, AND if old thread is not completely stripped than m7 should work. not sure if there's enough material for m8.
I've done one m6 to m7 and few m6 to m8 conversions on different places on engine and they all work fine for years."

My insert is gone too damaged and taken out. Putting helicoil in maybe too much metal needs drilled out? Is there another options or go up next bolt size with minimal enlarging.


Thanks

One thing I know is diameter needed for M6 helicoil insert is almost equals to diameter needed for M8 bolt.
So, there are two options - tapping existed hole with M7x1mm, or weld fill-up and then new thread.
I've done M6 to M7 tapping on the lower hole of oil filter housing, but in your case challenge is much shorter thread (not talking about tight area around, if the engine is on the bike).
anyways, I'd try it before welding - who knows, maybe it will work..

would simply drill the f$%^&d hole deeper, all the way to the cam chain cavity with a 4.8mm drill and tap the new deeper hole. use then a longer M6 bolt. if you have 6-8 mm of new threads it will be strong enough.


dismount alternator cover to aspirate the swarf falling into the chain passage.