I messed up (need clutch cover now)

[Loki]

Changed my clutch cylinder and while reinstalling my banjo bolt for the clutch line, i found out how sensitive the aluminum threads are...

Stripped them completely out. SOOOO i need a new clutch cover asap (have a track day next week). Does anyone have a clutch cover laying around lol.

O i was also making a video how to for the install and so i have video of me ******* up. Once it is done uploading it will be viewable, enjoy.

 

[Bolty]

The video is missing the part where you yell "****" and throw the wrench

 

[BuellyBagger]

heli-coil?? might b worth a shot. or tap the hole for a larger bushing that u can thread in and then thread the banjo fitting into that.

 

[Loki]

Yeah trying to see if someone around me has a helicoil kit.

 

[stensg]

I have one but unfortunately i need it previous owner dropped the bike

if you want a spare you can have this one when i swap them i know it doesn't help you now but maybe in the future. I have a clutch weep with it but it is a 08 so I'm not sure if its the damage that caused it or the piston

 

[Loki]

+1 for you stensg

I will try to repair it first, yours is very torn up

 

[P3_techman]

Ha. That really didn't take much did it? Thanks for the heads up, I will be performing this soon as well. My cover is torn up as well from where my buddy dropped it[down]. I don't think it is even that useful anymore. If you can't get it repaired, ASB has them for much cheaper than HD. I got mine off EBay though, lucky find new in the box.

HD part number: R1029A.1AM if all else fails. That is from an '09 parts manual.

 

[konarider94]

you are brave for posting that video...I would not have

 

[jstfkndi]

You are a very calm man. I have thrown and cussed for much less!

 

[stensg]

Maybe you could get it welded and tapped? I know my machine shop it would probably be less than 100

 

[konarider94]

http://badweatherbikers.com/buell/messages/21/690775.html?1345654502

maybe this guy hasnt sold his yet

 

[Loki]

Thanks for the replies guys!

Posting the video is a "whatever" thing, i broke it and i know, the video can help show how weak the aluminum threads are so others avoid what i did.

Also guy i found that amazon sells heilcoils kits for cheap! 20-30$
http://www.amazon.com/s/ref=nb_sb_noss_2?url=search-alias=aps&field-keywords=heilcoil

ALso through research alot of people say the heilcoils are stronger then the aluminum threads cause the coil is steal. They also say cause of this most aerospace aircraft use heilcoils from factory for their strength. That is good cause now i feel safer about using one.

 

[d_adams]

Not sure I'd trust a helicoil for a hydraulic (clutch) application, I doubt you'll get a good seal.

 

[OldGeezer]

A lot depends on how steady and accurate you are when drilling out the hole and tapping it before installing the helicoil. The helicoils are designed as in interference fit so that once installed they don't come out when you remove the fastener. If you drill & tap with a very steady hand and are well aligned you will get a good seal between the helicoil threads to the aluminium, however if your are concerned you can add some Loctite thread sealer to the outside of the helicoil before installing it.

The helicoils have a drive tang that must be removed once the coils are installed, be careful it doesn't fall into your clutch cover and get away from you The helicoils are usually made from stainless, so a magnet may not be able to pick it up depending on the grade of stainless.

Good luck

 

[stensg]

I've used coils but never removed the drive tang how do you remove them? I've needed them for sort screws.

 

[Loki]

Ok i found out what size the banjo bolt is and i think it is m10 1.25. Anyone know if this is correct? Looking it up this seems to be the correct size. NO stores around me sell pitch gages.

 

[BuellyBagger]

Not sure I'd trust a helicoil for a hydraulic (clutch) application, I doubt you'll get a good seal.

Use them all the time in aluminum oil pans on cars(when one the oil change boys f's up the threads for the drain plug)

 

[Loki]

Use them all the time in aluminum oil pans on cars(when one the oil change boys f's up the threads for the drain plug)

And they work great?

 

[konarider94]

the threads dont seal. the seal is created by the crush washer. you would just have to make sure the surface of the copper or aluminum gasket has something to seat on. typically the OD isnt a whole lot bigger than the ID for a bango bolt so there might not be enough room to helicoil it.

i like timeserts or threaded inserts a little better. in this instance you could use thread sealant on the insert and use the surface of the insert to get a good hydraulic seal with the crush washer. see this picture for the difference between the two. see how the timesert actually has a surface to it.

 

[Loki]

Ok everyone, got the heilcoil installed. Pretty easy. Was leaking slowly after install but i ran up to town and got some thread sealer and it worked great!

No leaks!