holy crap, Help! Please!

[kawaguy]

hi there guys, i have a 1999 kawasaki kx125, when i was changing the top end this weekend one of the cylinder base studs stripped and pulled itself out of the right side engine case, after pissing myself i ran down to the local engineering store to purchase a heli-coil kit, i repaired the thread and stuff and just as i went to tighten it up one last turn, it became easier and easier and holy crap there goes another fresh pair of joks, yea, it stripped the cases again, i did use the kit properly and it went in properly, is it new case time or is there a remedy, i was told by my dealer that the 1999 kx's had a tendency to strip out the studs, so he told me to drill out the hole straight throught to the clutch case, then just poke a bolt through the hole and ill be right, he had a bike in the shop that he had done it on, and it worked fine, no problems, but it looked like a butchers job, someone help me please!!!!!!!!!!!!!!!!!

 

[nickyd]

so what happened? The stud and the heli coil came out?

 

[kawaguy]

yea, the stud came out with the helicoil attached to it and the threads were mashed into the helicoil, what do you think i should do?

 

[Broken Spoke]

I agree with what the dealer said. It may not look as good, but it will get the job done. Another option is to tap the case with one size bigger tap, but then you would also have to drill out the hole through the jug to accept the larger stud.

 

[rm_dave]

Maybe you should of looked at some tighting torq specs. It may not of needed that last turn.

 

[ellandoh]

just drill enough to clean out the stripped threads a LITTLE BIT then tap it out .......it may end up an A.S.E. size then go to fastenal and get the proper stud...........

if not i once jb welded a spark plug into an 83 escort :coocoo: and it held for 2 years and sold it like that.......yes i told the buyer :boss:

 

[kawaguy]

yea hey guys, i drilled straight through and got a long enough bolt to poke through the top, it worked well, but yea, it doesnt look as good, but you only see it when the clutch case is off.

 

[crazy4nitro]

:ride: be done with it and FLOG!!!!!

 

[bclapham]

I agree with what the dealer said. It may not look as good, but it will get the job done. Another option is to tap the case with one size bigger tap, but then you would also have to drill out the hole through the jug to accept the larger stud.

might not have room for the nut if you do that.