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oh frak...


Guest lukebolger
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so i replaced the starter clutch - using the flywheel puller bought off ebay - which turned out to be the wrong one -


it damaged the thread on the flywheel bolt hole - so when i tried to put the bolt back in after changing the starter clutch it startred to crossthread - its ruined the first 5 runs...


but, the previous starter clutch looked absolutly fine, and even with the flywheel not bolted on it should if that was the issue turn over the engine but it still just turned the starter and flywheel gear thing but doesnt crank



im all out of ideas..



off to the local garage monday i think

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Mate, the couriers have broken something dropping it. Have you been in touch with them yet?


I am really annoyed, I handed over a fully working, non fairing smashed and fully indicator attached bike and that is not what you have received.

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probably too late to contact them now... even if I do I doubt they will admit to dropping it.


I dont doubt you did mate Its just one of those things I suppose, just hope they dont charge me too much to get it fixed.


Is it OK to tell the garage that I only have £200 in advance or is that a bad idea?

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probably too late to contact them now... even if I do I doubt they will admit to dropping it.


I dont doubt you did mate Its just one of those things I suppose, just hope they dont charge me too much to get it fixed.


Is it OK to tell the garage that I only have £200 in advance or is that a bad idea?

 

bad idea!! the repair bill will be £250, but they will 'do you a deal' and drop the price to £200..

Art of negotiation is dead...

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OK

Im very happy with myself :)


Found the problem! One way clutch sprocket needs re welding! Thats all!!


So tomorrow ill wheel it round to the town mech shop and hopefully they can re weld it and re bore and tap the threaded bolt hole

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OK

Im very happy with myself :)


Found the problem! One way clutch sprocket needs re welding! Thats all!!


So tomorrow ill wheel it round to the town mech shop and hopefully they can re weld it and re bore and tap the threaded bolt hole

Nice one mate....hope it gets sorted OK...... 8-) The bolt hole may need Helicoiling....but hopefully they can deal with that..... :wink:

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Colin, I was told on the EX-500 forum that the problem was defiantly my starter clutch.


and the website who sold me the puller claimed it was for my bike - I didnt know it would f**k the thread

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Colin, I was told on the EX-500 forum that the problem was defiantly my starter clutch.


and the website who sold me the puller claimed it was for my bike - I didnt know it would f**k the thread

 


You found the problem by taking it to bits and investigating. Well done. The internet is a good sounding board and can give you a heads up as to where the problem may lie, but you can't beat hands on and good old looking.


The puller did the job and the damage was caused by inappropriate use. Protecting the threaded hole with a bolt or a plate would be the way to go.


We learn by our mistakes is all I was saying and keeping your wits about you and your eyes open can help to not cause more problems as you go along. We've all done it.


If it's only the first five turns that are damaged it might be possible to drill out the end of the hole where it's damaged. It depends on how long the bolt is that's going in there and if there's enough thread left to hold it all together


.

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Cheers Colin, Ive given your drilling advice to the local mech shop - hopefully they can handle it - but as I said its a small town shop and they didnt seem to confident :s

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local mech shop cut the bolt up a bit then gave up...


they said ill need a new ENGINE


f**king hell


trying to get a trailor so i can take it some place else

 


Take some photos, lets see what you're dealing with.. if its just a few threads knackered, you might get away with it.

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its the first 3 threads on the inside of the where the bolt goes in to the crank on the flywheel side


ive ordered two new bolts (8 quid each!!)


there left hand threads


hopefully the garage tomorrow can re do it - they said they can (the one in the next town)


but now I need someone with a trailer!


So much hassle!

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its the first 3 threads on the inside of the where the bolt goes in to the crank on the flywheel side


ive ordered two new bolts (8 quid each!!)


there left hand threads


hopefully the garage tomorrow can re do it - they said they can (the one in the next town)


but now I need someone with a trailer!


So much hassle!

 

My bet would be that if its just the first three threads, and there are enough undamaged threads, they will just cleanup the damaged threads, and bolt it up with a load of threadlock!!

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i counted, the bolt has 20 runs, 4 are f**ked, 16 are fine, same on the inside - or even less f**ked on the inside


they should be able to counter sink it i would have thought, instead of re tapping.


problem is it the first garage cut the bolt down to 16 runs - so will it hold? i have a new one on order but it will probably take ages to rrive

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If you have one good bolt that is the correct thread for the damaged bolt hole, you can use it as a "tap" to clean up the damaged thread. Put head of bolt horizontally in a vice. Use a hacksaw with a new blade to cut a slot about 2mm deep at a 45 degree angle on the threads. Turn the bolt in the vice by two flats , 120 degrees, and repeat the hacksawing. Repeat again and you will have a bolt with 3 sets of cutting edges on it. Next, file the end 3 threads so that the first has almost gone, the second is a bit higher and the 3rd is nearly complete. You now have a tapered start to your bolt. Lastly clean the threads and cuts with a wire brush.

You now have a bolt that you can use to clean up the damaged threads. Put a drop of oil on the bolt threads, then make sure it is at 90 degrees to the bolt hole and with firm pressure screw it into the hole.

If you think you can't do this , pop it in the post and I'll do it for you and post it straight back?

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thanks megawatt!


No need!


I payed the garage in the next town to pick it up - £30


They looked at it, said i would need a new engine :(


They tried cleaning up the bolt but nothing.


Then I suggested they counter sink the hole a bit to get past the f**ked up threads


So they got a metal drill and shaved off two of the threads with a drill slightly bigger than the hole -


Hey presto! It worked!


Let it not be said that I drove the bike home - After a boost start, as the battery was flat -


It didnt drive f**king perfect because I definitely didnt drive it! :D


After the bike got the 5 miles back to my place - it started fine, I checked just to make sure the welding on the sprocket held.


But leaving it for an hour and the battery is flat again - It looks like I may need a new battery?

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thanks megawatt!


No need!


I payed the garage in the next town to pick it up - £30


They looked at it, said i would need a new engine :(


They tried cleaning up the bolt but nothing.


Then I suggested they counter sink the hole a bit to get past the f**ked up threads


So they got a metal drill and shaved off two of the threads with a drill slightly bigger than the hole -


Hey presto! It worked!


Let it not be said that I drove the bike home - After a boost start, as the battery was flat -


It didnt drive f**king perfect because I definitely didnt drive it! :D


After the bike got the 5 miles back to my place - it started fine, I checked just to make sure the welding on the sprocket held.


But leaving it for an hour and the battery is flat again - It looks like I may need a new battery?

 

Good results its running again!! 8-)

Sad state of affairs when two sets of trained mechanics both said you "need a whole new engine" when all they needed to do is clean up the bolt hole...

Mechanics seem to have lost the ability to repair stuff, and just relay on replacing stuff with expensive new parts. real shame...


As for the battery, could be a dead battery. whats the voltage read when bike not running, and when running at 3k rpm?

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ill have to check thatr on saturday mate, bike is at my parents in the garage, as I havnt got a lock yet and it will get knicked at mine -


They first gave me the local (well, 20 miles away) motorbike shop, and they ALSO said, nope, no way! New engine! I was so depressed! How much would that cost!? and what a waste of a perfectly good engine just because a hole has TWO out of 20 threads squashed!

edit: so thats THREE sets of trained mechanics quite happy to write it off (and sell the engine for parts no doubt!)


I insisted since the engine was in their opinion "f**ked" they try the drilling and it frickin worked!


Unreal how much I had to do to persuade them to even try!


In retrospect I could have done it myself, he just used a 10mil metal drill bit and a cordless screwdriver and drilled for 5 seconds and it barlely shaved anything off this hardened crank but that was enough and the bolt went right in!!


Live and learn!

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