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Rocker Cover - Broken Stud

Discussion in 'The Garage' started by 650Burger, Feb 25, 2020.

  1. 5twins

    5twins XS650 Guru Top Contributor

    You need a bottoming tap. That's a tap that doesn't taper on the end very much. It will tap threads deeper into a blind hole before it hits bottom. And yes, there are special Helicoil bottoming taps. I found some on eBay and did this very repair.
  2. YamadudeXS650C

    YamadudeXS650C Central New York XS650 XS650.com Supporter Top Contributor

    My local autoparts store carries "kits" which include a few coils plus the proper bottoming tap for a good price, and they tell you which size drill bit to use.
    650Burger likes this.
  3. 650Burger

    650Burger XS650 Enthusiast

    `Great. That's where I messed up, I got a kit with a non bottoming tap. Thanks for your input, the helicoil saga continues.
    YamadudeXS650C and Paul Sutton like this.
  4. Machine

    Machine Race the wind Top Contributor

    Or you can just grind the tip off of your tap in hand. Grind it flat as high up on the cutting edge "lead in taper" as you desire. You should leave just a small amount of lead taper. You can cut threads nearly all the way to the flat bottom of the blind hole if you are careful
    YamadudeXS650C and Paul Sutton like this.
  5. 5twins

    5twins XS650 Guru Top Contributor

    I used the normal tap with more taper to start the hole (it's easier), then switched to the bottoming tap.
  6. jetmechmarty

    jetmechmarty XS650 Guru Top Contributor

  7. Steve C

    Steve C XS650 Enthusiast

    Here's the holes I had to fix from the (very ham fisted) PO. Timesert worked well. One hole was off center because he drilled into a broken piece of screw and the drill walked and wallered out the hole off center. Ended up taking it to a machine shop, they opened up the casting hole and rewelded it then I used the filter plate as a guide to drill a brand new hole and Timeserted it for good measure. I was lucky it was one of the holes that could be gotten at!!!
    I like that the insert sits a little below the surface. Remains to be seen it it's gonna leak...Knock wood!

    Attached Files:

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