Topic: Case Repair Specialist

[Ellz10]

As you can see the post bolt snapped off due my complete lack of common sense. And so I thought I would try a bolt extraction method. You can see how that turned out. I'm trying my best not to go insane because it ALWAYS seems to be one thing or another and I know that's just how it goes and there's a learning curve but I'm losing it. I know it's difficult to say based off one picture, but can this be remedied with a helicoil insertion?

Is there anyone that specializes in repairing cases from mistakes like mine? I'd rather not go thru the process of having to buy a new motor, because one, the numbers match (not a big deal, but I like this fact) and two, I don't want to waste the money.

[Kelly E]

It looks like there is plenty of material to support an insert style repair.

[HondaMan]

That should be 'fixable' with a new Helicoil. The hardest part will be in making the hole in just the right (centered) position. Use a new drill bit: if you get the Helicoil kit, they come with a new (and VERY sharp, as in: watch your fingers!) drill bit of the right size.

[Ellz10]

That should be 'fixable' with a new Helicoil. The hardest part will be in making the hole in just the right (centered) position. Use a new drill bit: if you get the Helicoil kit, they come with a new (and VERY sharp, as in: watch your fingers!) drill bit of the right size.

"Should be 'fixable'". Keyword there ugh. I will DEFINITELY not be doing it myself, my lack of skill is the reason I'm in this mess. I was thinking of taking it to my local machine shop, but I'm not sure they would use as much caution and care as I would, SO I think I might send it out to Ken at Cycle X and have them do it. Afterall they did drill out my broken Cylinder stud and insert a helicoil. They did a perfect job.

Or maybe it's not as difficult for a professional machine shop anywhere to be able to accomplish and I'm overthinking as usual.

[BenelliSEI]

Any good machine shop can repair with an insert (like a “helicoil”). Ask you local cycle shop where they send their parts for machining. Your not the first one to have these problems. We’ve all “been there - done that”.

[Prospect]

That's a quick fix for any machinist. They have the right tools and knowledge. Shouldn't be that expensive.

[Don R]

 One I drug home recently needs the same repair. It would jump into gear while kick starting it. Send an update when you get it figured out, then I'll know how too.

[Keith]

I am a big fan of timeserts.

[craz1]

I to would go with a timesert

[Stev-o]

Timesert....

https://www.timesert.com/

[Don R]

 I'll need to check the depth, I'm thinking 6m dia. I have a head that needs a few too.

[Ellz10]

So I ended up selecting one of the most reputable machine shops in my town and after talking to him on the phone, I brought the bottom case in for him to look at. He immediately said it wouldn't be a problem. I was unsure and he could sense my hesitancy and did a good job reassuring me. I could tell he'd been doing machine work for several decades and he seemed like a genuine nice gentleman. So he said to just give him an hour and he'd have it ready. I was shocked. I figured with workload and whatnot he'd have it for a few days. This suited me just fine, with my anxiousness and all. So I get the call that it's ready almost an hour on the nose and I ask if he threw a helicoil in and he said that he hadn't but he can if I decided that that's what I wanted after I inspected it. So I get there and sure as hell he got it out of there without a problem. He used a process I've never heard of, known as EDM (Electrical Discharge Machining). He went thru the process and explained how it all worked and I was totally geeking out, super cool stuff! Funny enough this gentleman who's shop it is, his son was there working too and I recognized him instantly; he was a good friend from high school! Small world! Anyways I brought the same size bolt with me and oddly enough it threads all the way thru even with a small chunk of the threads missing.

He asked me if I wanted him to put a helicoil in there and he could do it no problem and true it center and have it precisely center of where it needs to be (modern technology kinda amazes me sometimes) and I said that I would wait to get the replacement Post Bolt (Thank you HondaMan, as always coming in to save the day) and see how well it seems with some blue thread locker on there hand tightened as best I can get it. If I end up needing to or if the collective concensus from this thread is to definitely get the helicoil or based on the other comments, a timesert (never heard of this), then I'll go that route.

All in all I'm VERY happy and a huge weight of stress was lifted off my shoulders after he was able to get it run. I was unbelievably stressed and I thought the whole case  was going to be junk, ect. And a bonus is that he only charged me $30. I gave him 40 instead and he split it with his son right there on the spot. I will definitely be going back to them in the future when, not if, I break off another bolt haha!

[Ellz10]

I'll need to check the depth, I'm thinking 6m dia. I have a head that needs a few too.

Yes Don it's a 6mm bolt size

[bryanj]

Otherwise known as spark erosion

[HondaMan]

Well, well! You're lucky to have someone near you who does EDM. I didn't recommend it as it is rare around here, and the guys who do it think they are gods or something, charging $100+ per hour to do anything with it. I once send a case to another State, had them EDM it (4 holes) and send it back, and it didn't cost that much.

[Ellz10]

Well, well! You're lucky to have someone near you who does EDM. I didn't recommend it as it is rare around here, and the guys who do it think they are gods or something, charging $100+ per hour to do anything with it. I once send a case to another State, had them EDM it (4 holes) and send it back, and it didn't cost that much.

Yeah, very blessed. I never knew it was a thing. I'm still debating whether or not to do a helicoil. Going to wait to get the post bolt, throw some threadlock on it and see how it holds up once screwed in. I'll let ya know!

[thep1pe]

Put a helicoil in it’s easy to do and will strengthen the new bolt/stud. It will also put your mind at rest.

[HondaMan]

Well, well! You're lucky to have someone near you who does EDM. I didn't recommend it as it is rare around here, and the guys who do it think they are gods or something, charging $100+ per hour to do anything with it. I once send a case to another State, had them EDM it (4 holes) and send it back, and it didn't cost that much.

Yeah, very blessed. I never knew it was a thing. I'm still debating whether or not to do a helicoil. Going to wait to get the post bolt, throw some threadlock on it and see how it holds up once screwed in. I'll let ya know!

There's no need for threadlocking compound on it. In operation, every time you upshift the engine it will tend to tighten the stud a little bit if it was trying to loosen up. Honda does that sort of thing (or did, in the 1960s-1980s designs). I've never seen one of them even a tiny bit loose, but have seen them stuck pretty tight on first disassembly.

[Ellz10]

Put a helicoil in it’s easy to do and will strengthen the new bolt/stud. It will also put your mind at rest.

See this is what I'm thinking. But at the same time I'm not sure I want to risk something going wrong. Just not sure ugh

Well, well! You're lucky to have someone near you who does EDM. I didn't recommend it as it is rare around here, and the guys who do it think they are gods or something, charging $100+ per hour to do anything with it. I once send a case to another State, had them EDM it (4 holes) and send it back, and it didn't cost that much.

Yeah, very blessed. I never knew it was a thing. I'm still debating whether or not to do a helicoil. Going to wait to get the post bolt, throw some threadlock on it and see how it holds up once screwed in. I'll let ya know!

There's no need for threadlocking compound on it. In operation, every time you upshift the engine it will tend to tighten the stud a little bit if it was trying to loosen up. Honda does that sort of thing (or did, in the 1960s-1980s designs). I've never seen one of them even a tiny bit loose, but have seen them stuck pretty tight on first disassembly.

Did not know this, thank you. So no to the threadlocker, thank you! Once again you impart valuable knowledge, many thanks!