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Sportster Motorcycle - Bottom End Cams, Cases, Gears, Flywheel, Piston Conecting Rods, Oil Pump, etc...

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  #1  
Old 24th August 2018
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Default need advice (Head/Case Stud Loose)

Found a head/case stud loose. It's the same one I already repaired with a time-sert. The case is stripped again. Now to the size of the time-sert so I can't use a normal time-sert to repair it. Do they make a bigger size? Would that even be safe? There's still a bit of thread in there. but not enough to torque down. I was even considering jb weld. But that seems like a bad idea. Help's appreciated.
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Old 24th August 2018
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Quote:
Originally Posted by _Outlaw View Post
Found a head/case stud loose. It's the same one I already repaired with a time-sert. The case is stripped again. Now to the size of the time-sert so I can't use a normal time-sert to repair it. Do they make a bigger size? Would that even be safe? There's still a bit of thread in there. but not enough to torque down. I was even considering jb weld. But that seems like a bad idea. Help's appreciated.
I had exactly the same situation, when case thread damage was so bad there wasn't enough material left for OD of the Time-sert insert, or, better to say, the quality of remaining material was poor. Found it out while torqueing the head bolts.

Ended up with a custom-made threaded insert with m14x2 outside thread (.551" OD). I only have about 2K miles on it, but so far - so good, even on my bored for 90" cylinders cases.

That's with cast iron cylinders, don't know if it will be any different with sleeved aluminum ones.
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Old 25th August 2018
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if your case is coated, this is not for you.
with some heat dam putty, jeweler torch and some aluminum braze rod you can do a fill in. if you control the heat, the braze will hold, make sure it is squeaky clean first. there is tig and mig also. you could go with the insert if the case has material to hold it.
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Old 28th August 2018
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Alright. After a lot of research and a bit of stressing, I decided on a keensert. It should be just big enough for me to drill and tap new thread once again. keensert just came in today. Gunna start on it in a few minutes probably.
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Old 29th August 2018
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Keensert pulled out when I was torquing it down. I think there wasn't enough material left for the keensert. Have a bigsert on order now. Hopefully that works. Should have started with the big sert. Going from keensert to bigsert may have the same issue.
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Old 1st September 2018
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Alright. Just got the big sert torqued down without pulling it out of the case. If anyone's curious the outside threads of the big sert are metric. 14mm x 1.5 thread. 31/64 drill bit works. 14mm x 1.5 calls for 12.5mm hole. Good luck finding that locally. 31/64" is 12.3mm.

I bought the 1" big sert, but I might recommend getting the 1/2" cause it was pretty nerve wracking driving a tap that far into my case.

Moral of the story, don't use a keen sert if you've already stripped out a time sert.
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