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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #1  
Old 14th November 2005
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Robohead Robohead is offline
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Default Stripped threads in primary cover

Hey Guys and Gals, I'm new to the board here. I have 2000 XL1200C. I bought a new HD logo derby cover the other day. I installed it last night. No problem there, but when I went to put the 4 torx bolts back in, the bottom one stripped out. I did not over tighten it, it just gave out very easily. This is the hole that is stripped, not the bolt. So my question is.....what are my options? I don't want to replace the entire primary cover if I don't have to. Can the hole be drilled bigger and tapped and then insert a sleeve that would fill the gap? I did this years ago when my VW bug blew out the spark plug hole threads. I have no idea if it can be done on such a small scale though. Are there any other options out there? It is leaking right now, so I'm not riding until it's fixed. Any advice would be appreciated. TIA

Ron
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  #2  
Old 14th November 2005
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Hi, welcome aboard.

I am sure you can get thread inserts for this. I hear it is quite a common problem. It will entail drilling, tapping and insertion of a thread insert.

Cheers,

Brett
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Old 14th November 2005
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Heli-Coil is the one i hear about the most.

What you might try tho first is to just run a same-size tap in the hole. Sometimes i have found in these cases there is still enough threads, once repaired, to hold the bolt. Then use a new bolt, with blue LokTite, tighten just to firm.
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Old 14th November 2005
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Get a self tapping screw ... easy
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Old 14th November 2005
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Get rid of the torx bolts and get a good set of stainless allen bolts. I've had my derby cover offf so many times I stripped the heads on the torx long ago and had to drill and use an easy out to get them out before I replaced with the stainless.

Bob
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Old 14th November 2005
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One word....Heli-coil.
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  #7  
Old 14th November 2005
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Same happened to me on my '00 XLH. When I inspected the threads I found the only the first 1/4 inch was stripped and that I had a full inch of threads in the hole. Longer screws did the trick for me.
Hope this helps.
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Old 14th November 2005
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Theres even a easyer way, get you some peratex striped thread repair compond. It comes in a two part epoxy type stuff that you mix together and put it in the stripped hole, then there a releaseing agent that you put on the screw. Then after putting the releaseing agent on the screw, screw it in. then wait about ten mins. Then you can unscrew it and the stripped threads will have reformed. Just don't tighten the shit out of it, just snuge it up a little thats all it takes!
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  #9  
Old 15th November 2005
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Thanks for all the suggestions. The threads were far to gone to re-tap. They actually came out with the bolt when they stripped. After seeing the first response, I went down to Autozone and found a 'fix-a-thread' kit. It came with a 1/4" heli-coil insert, a tap and a coil installation tool. Cost $19. All I had to do was drill out what was left of the existing threads, tap the new hole and install the heli-coil. Took 10 mins and worked like a charm. I do like the idea of replacing the torx bolts with allen bolts. That's next on my list. Thanks again for all the input. This is definitely the place to go for answers.
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  #10  
Old 15th November 2005
gvd883r gvd883r is offline
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my threads stripped also, longer 3/4" length bolts worked for me.
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