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Message started by heroicseven on 06/22/12 at 20:19:40

Title: Plug cap woes.. Help?
Post by heroicseven on 06/22/12 at 20:19:40

I just pulled the head cover to replace the plug cap whilst the bike got a verslavy and now I have noticed that one of my bolts appears to have stripped out. To clarify the bolt is fine, the head is stripped :'(

any suggestions/ possible solutions?

the bolt in question is the L60 bolt.

Title: Re: Plug cap woes.. Help?
Post by Oldfeller on 06/22/12 at 22:27:10

Go buy a 65mm long bolt, or a 66mm long bolt -- there are extra threads tapped into the head and you just need a longer bolt to reach down to engage them.

Title: Re: Plug cap woes.. Help?
Post by heroicseven on 06/22/12 at 23:09:32

thank you sir, you just made my month. ;D

What can be done to prevent this in the future? Seems like eventually Its gonna be stripped entirely. :-/ Guess I could just get a lancer's over bore kit and call it a day. ;)

Title: Re: Plug cap woes.. Help?
Post by verslagen1 on 06/22/12 at 23:14:22

24293E23252F3F293A29224C0 wrote:

one of my bolts appears to have stripped out. To clarify the bolt is fine, the head is stripped

The head is where the socket goes... the threads are the threads.

if you just messed up the flats you can file the flats to the next size down or get the same bolt. yes, a little longer will give you more engagement but do you need it?

Title: Re: Plug cap woes.. Help?
Post by rfw2003 on 06/22/12 at 23:17:13

verslagen1, when he says Head I think he's talking about the threads in the jug itself not the head of the bolt.

Title: Re: Plug cap woes.. Help?
Post by heroicseven on 06/22/12 at 23:26:14

as it is currently the L65 bolt is in perfect shape. However when it is inserted into the head it spins freely,, well with some resistance but just barely enough to inhibit turning by hand. when a wrench is applied it spins like a top, so I feel the longer threading may go down to some of the un-stripped threads in the head, and secure the head cover.

I can't seem to wrap my head around your references to "flats" Im a total newb to the whole mechanical world. so if you don't mind explaining that a bit in terms a 8 year old would understand, I would love to learn what your referencing.

Title: Re: Plug cap woes.. Help?
Post by heroicseven on 06/22/12 at 23:29:15

293D2C696B6B685B0 wrote:

verslagen1, when he says Head I think he's talking about the threads in the jug itself not the head of the bolt.

I just connected the dots about the flats, got it. And yes its the jug thats buggerd up.

Title: Re: Plug cap woes.. Help?
Post by rfw2003 on 06/22/12 at 23:33:26

When you do eventually do a Lancer overbore or rebuild I would suggest either you putting a heli-coil in or have it done. That way you know you will have good threads for the full engagement.

R.F.

Title: Re: Plug cap woes.. Help?
Post by verslagen1 on 06/22/12 at 23:51:45

oh.... nevermind ;D

Title: Re: Plug cap woes.. Help?
Post by heroicseven on 06/23/12 at 00:31:27

thanks for the suggestions. ;D the heli coil looks interesting as a solution, may be a bit tricky with the depth of that particular bolt. Have you used it yet?

Title: Re: Plug cap woes.. Help?
Post by rfw2003 on 06/23/12 at 00:50:48

2825322F2923332536252E400 wrote:

thanks for the suggestions. ;D the heli coil looks interesting as a solution, may be a bit tricky with the depth of that particular bolt. Have you used it yet?

while I haven't used them on this bike, I've used them in similar situations before and they work wonders. Most of your aluminum automotive engines use them from the factory for the head and main bolt threads in the block as well.

To use one in your situation you will have to take the head off the bike so you can drill out to the proper size for tapping it for the heli-coil. Also if you do this yourself use some Red locktite on the heli-coil for it's install. After you have the heli-coil installed just reassemble your engine and your good to go.

R.F.

Title: Re: Plug cap woes.. Help?
Post by 360k+ on 06/23/12 at 08:17:15

7E7364797F756573607378160 wrote:

thanks for the suggestions. ;D the heli coil looks interesting as a solution, may be a bit tricky with the depth of that particular bolt. Have you used it yet?

I don't know if you have this already, but I have a parts fiche on PDF with exploded views of the whole bike (I may even have gotten it here?). If you need, I can attach and send to your email. It's fairly large ~5.5meg, so kids, don't try this on dialup.

Title: Re: Plug cap woes.. Help?
Post by justin_o_guy2 on 06/23/12 at 08:24:25

Id get a long bolt & find where the top of the good threads are & mark it.
Id take a fine piece of hard wire & find the bottom of the threads & mark that & see if theres enough thread in there to use.
A bend ta the end of the wire to make it drag will let you find the bottom thread.
Or, you could take a bolt & use a grinder on all but the bottom 2 or 3 threads. Screw that in & youll find the bottom thread.