Stripped Head Bolt - 900 RMK

[iowanodak]

I put the stock head back on my 900 and was torquing the bolts down to 18# and one never tightened. When I pulled the bolt out over an inch of threads came out with it. The farthest left front bolt is the one that is stripped. The bolt will stay in there and is somewhat tight, but I'm worried it will vibrate loose and coolant will come from the hole.

- Should I check depth and see if a longer bolt will work?
- Just retap to next larger size? Are the cylinder & coolant walls thick enough for this?
- Try a helicoil?
- Any ideas?

Thanks,
Iowanodak

 

[BIGGDAWG]

the holes go all the way to the coolant passages most of them you can use a longer bolt except the ones by the exhaust valve/port. if it is one of those i would helicoil it. you can helicoil any of them that is the best repair and longest lasting.

 

[skibreeze]

Helicoil is the correct way to fix it. Make sure to use locktite when putting it in.

 

[benamen]

What type of Loctite is recommended for the inserts? I just used one a couple of weeks ago and did not loctite it in.

 

[sled_guy]

I actually prefer kingserts over helicoils. They thread in and then have a set of pins you drive in to lock them in place.

sled_guy

 

[BIGGDAWG]

What type of Loctite is recommended for the inserts? I just used one a couple of weeks ago and did not loctite it in.

i use blue but red is fine also

 

[iowanodak]

I'll start with the easy route and see if I have the depth for a longer bolt. I'm worried about the use of a Keensert or helicoil because they would either require drilling the hole bigger which is risky or if I leave the hole the same size and put one in, then I would have to use a smaller bolt. If I go the smaller bolt route I would have to use a Grade 8 or stronger bolt. I'll post my final solution.

 

[Franz]

Actually the drill will want to follow the existing hole. Even better if the drill isn't in perfect condition. Just use common sense with the drill. Stick a bolt in a good hole and use that as a gauge to angle the drill correctly.

 

[skibreeze]

Dude, just put a helicoil in and be done with it. It's not rocket science and not that difficult.

 

[Redd]

If it were me, I would use a helicoil, I've always had good luck with a good quaity helicoil. I learned this by triin' to skimp on things and it failing.
Red locktite imo.

 

[machineman]

Keen serts are too big and will interfere with the o-ring grooves. heli-coil is best for this but it can break into the groove also. The cheapest and best insurance it to not use the bolts at all. The cast alm. is very pourous material and can only take so many torque cycles. The pull and twist is what strips them. I always replace my bolts with studs and copper washers. the straight pull on the threads w/o rotation and they will live forever. Always use neverseize on any alm. threads! How many 2-cycle dirt bikes have bolts?

 

[iowanodak]

I put a 10mm longer bolt in, with red loctite, blue gasket silicone at the top, torqued it down to 15 ft lbs and marked the bolt and head to make sure the bolt does not turn. Rode 100 miles yesterday and it is still good. I wanted to go the helicoil route but $60 for one size helicoil/tap kit locally was too much for me, I didn't check online due to time it would take to get here. I plan to helicoil it when I find someone with the kit or find a kit reasonable.
The test will be this weekend, should be putting on ~250 miles, will let know if it fails.

 

[indydan]

Dude, just put a helicoil in and be done with it. It's not rocket science and not that difficult.

LMAO!!!!!! Thats a fact !!!! red loctie and 15 ft LBs what a hack job

Do you have a tow rode ???

 

[diamonddave]

LMAO!!!!!! Thats a fact !!!! red loctie and 15 ft LBs what a hack job

Do you have a tow rode ???

Sometimes you have to spend a little money to save big money

 

[triple650]

now i dont know why poeple are saying to use something as if it would be common sense, to some it may be, but i dont even know what a helicoil is? i didnt think it was a crime to not know everything.

 

[Redd]

now i dont know why poeple are saying to use something as if it would be common sense, to some it may be, but i dont even know what a helicoil is? i didnt think it was a crime to not know everything.

I'm with you, I know some but not all, that's why I try to soak in as much as I can! (I do know what a helicoil is)

 

[indydan]

now i dont know why poeple are saying to use something as if it would be common sense, to some it may be, but i dont even know what a helicoil is? i didnt think it was a crime to not know everything.

Sorry Kid, I never thought someone won't know what a heli coil was.

 

[triple650]

Sorry Kid, I never thought someone won't know what a heli coil was.

Yea well i dont, and theres lots i dont know. Im sure theres stuff out there that you dont know about that i may know about. You cant just assume everyone knows everything.

And i dont mean that in disrespect, i know what you have done, and what you do, and ive even talked to you once on the phone. But for me its insulting when someone says to use something as if it were common sense, and makes me feel stupid because i didnt know what it was, or thats what i was supose to do. Just saying.

Justin.

 

[iowanodak]

Ouch, ouch, come on guys have some faith in my band-aid fix. I got a weekend in and another day ride, little over 300 miles, with the longer bolt and had no problems. I found a metric helicoil kit for a reasonable price and when I had time I installed the M8x1.25 helicoil without any problems....that is the original size and allowed me to use the original bolt.
Those of you that have similar problems go with the helicoil especially in aluminum. My band-aid fix worked this time but may not always and definately would not last long term. So take your time and do it right is the best advise as many of the other guys suggested.