update on my shovel...

Well, the old FXS seems to be running sweetly, whirring away (i've decided that it's more like a whining noise, but since it only happens at 1500rpm, the answer seems to be don't ride at 1500rpm...). Just waiting for my next spending spree to arrive, a cobra seat and a crane ignition module. In the meanwhile, i decided to isolate the primary drive oiling system, and i'm glad i did, as when i removed the magnetic drain plug it was covered in little bits of metal. Sadly on re-fitting it the threads stripped (don't think it was all me since i was using a torque wrench). I have made a temporary repair with a rubber bung and drawbolt which compresses the bung once in the hole and tightens it all up. But i will at some point have to helicoil the hole and it looks like a bit of a bugger being where it is. Anyone done this before?

[Chiefy]

Never had to Helicoil this particular hole but it might be worth taking the case off the bike to do the job. Other than that Helicoiling is fairly straightforward, like all matters engineering, take your time, get set up and check everything before you start drilling the hole out. Another little tip is to find a method of marking the Helicoil tap so that you don't mix it up with other taps that you may have.

[the_french_owl]

Yougjon,

If you're careful, you can helicoil in situ: cover the tap with lot of grease, only tap one turn at a time, wisdraw, clean tap, more grease etc... That way, it's unlikely any bits will stay in the cases.

Patrick

I'm ok about the swarf, it's the alignment that i'm concerned about. Does anyone know if the helicoil (or other brand) drills/taps have any kind of pilot extension to begin with, to guide it straight?

[Chiefy]

I think that most on offer are pretty standard offerings, In 30 years of engineering I've not seen an Insert Tap or drill that looks any different to a normal one.

You could start with a drill a size down from the final one, in the hope it will have less metal to remove and will follow the existing hole a little easier. As for the tap, then it would have to be eyeball time.

It was the alignment issue that lead me to advise removing the case, once it's off the bike at least you can get comfortable, get the thing set up better and be able to see exactly whats going on when you start cutting metal, especially the Tapping operation. The swarf issue goes away as well.

whilst there's talk of helicoils. i need to helicoil the mount for the kicker spring hook in the kicker cover. but i've no idea what the thread is on the little pillar that screws into the case. threads abit mashed on the existing one, so i can't measure it. the holes abit mashed too, but i think it's still small enough to get a good fit with a heli.

i want to invest in a heli kit and do it myself. those things are always useful to have around for the unexpected. any experiences of kits etc.

thanks in advance.