XR650R Thread!

[Toaliosis]

Originally Posted by jesusgatos

Drill it out larger and insert heli-coils.

As easy as this sounds, I don't think it will work since the Helicoil tap is too short.
I can't see a way to get the tap tool on the tap to get a straight thread cut.
Maybe someone can enlighten me....
Other wise I think I'll be going with the swing arm buddy kit.

[Cpt. Ron]

Originally Posted by Toaliosis

As easy as this sounds, I don't think it will work since the Helicoil tap is too short.
I can't see a way to get the tap tool on the tap to get a straight thread cut.
Maybe someone can enlighten me....
Other wise I think I'll be going with the swing arm buddy kit.

Open-ended wrench. In a pinch, a Crescent wrench. If you do go with that, get a metric one...

[Toaliosis]

Originally Posted by Cpt. Ron

In a pinch, a Crescent wrench. If you do go with that, get a metric one...

Very funny.
I'm curious if the wrench idea will give a straight tap....

[hontri]

Originally Posted by Toaliosis

As easy as this sounds, I don't think it will work since the Helicoil tap is too short.
I can't see a way to get the tap tool on the tap to get a straight thread cut.
Maybe someone can enlighten me....
Other wise I think I'll be going with the swing arm buddy kit.

I hate being defeated. If it were me i would cut the end off the tap using an angle head grinder with a cut off wheel then carefully grind a couple of flats on the now (shorter tap) to suit the open end wrench you will be using. But that's me

[Mur]

I just went through the exact same thing you are going through, last week. It was only a semi-headache. lol.

I used an open end wrench and it tapped just fine... I'm sure the steel heli coil will work alot better with steel bolts,not that I didn't smother them in anti seize,and drill a drain hole Oh, and I used Red Loc-tite on the new heli coil threads I put in, just to make sure they didn't go anywhere. Something I read somewhere.
Patience was key with this one.


EDIT: I see the problem you're having,now. With the tap being too close to the swing arm...

[bill pierce]

Originally Posted by hontri

I hate being defeated. If it were me i would cut the end off the tap using an angle head grinder with a cut off wheel then carefully grind a couple of flats on the now (shorter tap) to suit the open end wrench you will be using. But that's me

The flats of that tap are right against the aluminum with the tap straight. As soon as it is turned 1/8 turn it won't be straight again. Don't think that's going to work.

Some machine tool suppliers stock or can order you a "long tap" allows you to get into a hole like that. I have a few in standard sizes.

[ODSC1]

Originally Posted by Toaliosis

As easy as this sounds, I don't think it will work since the Helicoil tap is too short.
I can't see a way to get the tap tool on the tap to get a straight thread cut.
Maybe someone can enlighten me....
Other wise I think I'll be going with the swing arm buddy kit.

Weld a short 1/4 drive extension on to the end of the tap. I had a tool like this made up at work to tap out the stock holes. Just used it again last week. Works perfect.


Brian

[EduardoMas]

In the 1st pic the hole seems off-centre. On the second pic it seems that the tap is crooked towards the arm at the shank side.

If the square of the shank is not already ¼” or just under, use a grinder to take material off all four sides and then use a ¼” socket driver extension. You can get a cheap one and grind the OD if you need to.

Put the extension on the tap and use a tap handle or even a wrench on the ¼” male side.


When specifying inserts (at work) I only use helicoils for occasional use. For higher service I rather use Time Serts for repairs. Higher cost, but reliable in the long run. Then there are E-Z lok, great as an OEM choice, but they need more material to tap a larger thread.

Good luck.

[EduardoMas]

Hey Brian :-)
I have your tools... will you make it to the Bike show in TO?

[ODSC1]

Originally Posted by EduardoMas

Hey Brian :-)
I have your tools... will you make it to the Bike show in TO?

Hi Eduardo!

Won't be at the show this year. Leaving for Central America on Wednesday with the new XR(05) . Back at the end of January.

[EduardoMas]

Originally Posted by ODSC1

Hi Eduardo!

Won't be at the show this year. Leaving for Central America on Wednesday with the new XR(05) . Back at the end of January.

Just sent a PM at the ODSC with Garmin tracks from 2005 with some advice on how to follow it. If nothing else, it shows the beginning and end of some trails. Look at them on google maps and see if you find them useful.

Enjoy the south!

[Toaliosis]

Originally Posted by bill pierce

Some machine tool suppliers stock or can order you a "long tap" allows you to get into a hole like that. I have a few in standard sizes.

As I’m finding out the Helicoil taps aren’t “standard” sizes, I don’t believe a “long tap” exists for it.

Originally Posted by ODSC1

Weld a short 1/4 drive extension on to the end of the tap. I had a tool like this made up at work to tap out the stock holes. Just used it again last week. Works perfect.

I don’t have a welder but my buddy does…might have to take a trip to see him.

Originally Posted by EduardoMas

In the 1st pic the hole seems off-centre. On the second pic it seems that the tap is crooked towards the arm at the shank side.

Originally Posted by EduardoMas

If the square of the shank is not already ¼” or just under, use a grinder to take material off all four sides and then use a ¼” socket driver extension. You can get a cheap one and grind the OD if you need to. Put the extension on the tap and use a tap handle or even a wrench on the ¼” male side.

I just set the tap in the hole for picture purposed, I had begun tapping it yet hence why the tap appears to be cattywampus. The flat side of the tap is extremely close to the swing arm, I doubt grinding and then shaving down an extension would give me the clearance I need.

Thanks everyone for their input. I’m going to try welding the extension on to the tap. I'll let you know how it works out.

[larryboy]

Originally Posted by Toaliosis

Thanks everyone for their input. I’m going to try welding the extension on to the tap. I'll let you know how it works out.

Don't do that, just throw it in the chop saw and cut the tap in half, grind some new flat spots into it until a 12 point socket fits, it'll be in the area where the axle goes then and a socket will clear.

Wham, bam, thank you ma'am, all done.

[ride4fun562]

Women drive like shit and do not understand right of way, they would be completely usless if they did not have vaginas. That is all

[medisyn]

Originally Posted by ride4fun562

Women drive like shit and do not understand right of way, they would be completely usless if they did not have vaginas. That is all

Is the XR ok?