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Sportster Motorcycle General Discussion and Problems For discussing problems about your Sportster motorcycle that don't fit anywhere else.

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  #1  
Old 3rd April 2011
AsSeenOnTV AsSeenOnTV is offline
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Default My own Time-Sert installation thread

After reading a great thread posted by Fergerburger about installing a Helicoil on his stripped out timer
cover hole, I decided to try my hand at something similar.

First, I have to give credit where credit is due, here is Fergerburgers thread about 'thread repair' :

http://xlforum.net/forums/s....php?t=1071324

While I'm am getting my bike ready for spring, I had cleaned and reoiled my air filter and was placing the
backing plate back on, when I felt one of the 3 bolts started going south on me.Yep, sure enough, it had
stripped out.

Fergerburgers 'How to' thread made It look so easy I decided I could try something like that. After much
research , I opted for the Time-Sert repair kit.

So here is my own 'How to install a Time-Sert' for other noobs like me.
WARNING, this can be a difficult job and you could easily screw up something more than what the
stripped out hole was already. Practice on something before you take this on. Before I tried it on something
important to me as my bike, I practiced on my bosses airplane!

This is the kit I found on E-bay. A little more expensive than the helicoil repair kit. But stronger, and
something i think I couldn't screw up as easily.




I also purchased this guide to help keep my tap straight:


You will need a tap wrench, there are several kinds to chose from. I used this one:


The instructions in my kit said to use oil. Before I even attempted this job, I did a lot of research. I
learned that grease works better, and keeps the metal shavings in control. So get some grease before
you start tapping:


You will also need several rags to help keep the mess down and your hands clean. Also cover up your
intake as well as the breather holes so you don't get any metal shavings in your engine:


After a break in the weather, I was ready. Now take the drill bit that came with the kit, and tighten it
down into your tap handle like this:


After you grease up the drill bit, you are ready to begin. Here is my drilled out holes on my bike, and
the mess I am talking about:


You start drilling out the stripped threads, going forwards one turn, and backing out a half a turn.
Occasionally you back the bit out all the way, and clean up the flutes. This is where the rags start to
come in handy:


Once the old threads are gone, you remove the drill bit from your tap wrench, and put the countersink bit
that came with the kit. This is the countersink bit:


I used a hand drill on this one. This is where the job gets really messy, and shavings will get everywhere.
Grease up the bit to help collect the shavings:


Here is my first of three holes I needed to countersink already finished:


And this is it after it has all been cleaned up and ready for the next process:


The next stage is using the thread tap die that came in the kit:


Here it is in my tap wrench:


Here is the tap bit with the guide all ready to go:


And here it is all greased and ready to use:


This is very critical. DO NOT let the tap wiggle, or you could ruin your threads you are making with
it. Hold it steady. here it is all the way in:


Once I tapped all three holes, I cleaned it up for the next process:


Its time to install the Time-Sert and finish the job. This is a Time-Sert. It is made of steel, and when
finished, will make it much harder to strip out again:


Now is where you use some good oil and start screwing the Time-Sert into the new threads by hand:


Then you take the tap wrench and put on the Time-Sert insertion tool, as seen here:


Keep on turning it in until the bit has gone all the way through. The insert is being counter sunk and
then 'cold rolled' into the walls of the aluminum:


You can see the insertion tool protruding through to the other side:


You are now finished. here is what it looks like with the Time-Sert install completed:


This seemed scary at first, but after much research I was able to do this myself. Before you attempt this
I advise you do your own reading and learning before you work on something important. if done wrong
you can mess it up more than it was before.

Last edited by AsSeenOnTV; 5th April 2011 at 00:19..
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Old 3rd April 2011
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It's so easy, even a girl can do it!!!!

Noice job, Shelle!
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Old 3rd April 2011
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"This seemed scary at first,"......Good for you....some people never get past that point....when learning/attempting a new skill I just roll up my sleeves and tell my self ....thousands of dumb asses before me have done this task and I'm at least as dumb as them !!! LOL
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Old 3rd April 2011
AsSeenOnTV AsSeenOnTV is offline
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Quote:
Originally Posted by EL in NH View Post
"This seemed scary at first,"......Good for you....some people never get past that point....when learning/attempting a new skill I just roll up my sleeves and tell my self ....thousands of dumb asses before me have done this task and I'm at least as dumb as them !!! LOL
Usually it takes me about a month of researching on the internet before I attempt something on my bike. Next job is rocker box gaskets.
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Old 3rd April 2011
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A Girl fixes a Girls bike !
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Old 3rd April 2011
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Quote:
Originally Posted by shotgun46 View Post
A Girl fixes a Girls bike !
I can even 'brake' them!
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Old 3rd April 2011
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Quote:
Originally Posted by AsSeenOnTV View Post
Usually it takes me about a month of researching on the internet before I attempt something on my bike. Next job is rocker box gaskets.
I have no doubt you can handle it,,just remember when working with steel fasteners in aluminum threads...tighten till it strips and back off a quarter turn... ... ah hell you already know that

ps nice pics !!

Last edited by EL in NH; 3rd April 2011 at 03:36.. Reason: why not
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Old 3rd April 2011
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I like it . i like to see that ladies can fix there ride's too!!!!!
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Old 3rd April 2011
AsSeenOnTV AsSeenOnTV is offline
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Quote:
Originally Posted by EL in NH View Post
.....,just remember when working with steel fasteners in aluminum threads...tighten till it strips and back off a quarter turn... ...
Now you tell me!
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  #10  
Old 3rd April 2011
Brad Brad is offline
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Not bad for a girl!

Last edited by Brad; 3rd April 2011 at 21:28..
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