Z1000J Camcap bolts

[LeeJackson]

Ordered up some helicoils with various lengths. The ones that were in were 8mm long and I'm thinking you can get something a little longer in which may help as well. Just noticed I cracked a bit of the webbing on number 2 cap as well.. Eek! Anyway reading some previous threads it seems that's likely not a huge problem so I think ok to continue Vs swapping. Hopefully!

[Al]

I was initially looking at Timeserts, which due to their nature are significantly stronger than helicoils, but may cause an interference problem with the buckets in the same manner as Al has suggested if tapped to M8 as they're a larger diameter. I would seriously consider M7 bolts

Quite a few people have used M8 timeserts on here to repair J threads but i suspect that its only OK if they are set high up immediately under the counterbore for the dowels.
On that subject; 7mm bolts may not fit through the dowels!

Just noticed I cracked a bit of the webbing on number 2 cap as well.. Eek! Anyway reading some previous threads it seems that's likely not a huge problem so I think ok to continue Vs swapping

If it was caps 1 or 3 it would be an issue because the webbing there has another function but the webbing of 2 and 4 make no contribution to the security of the cams or integrity of the make up of the two piece bearing arrangement.
Does the crack extend from the webbing into the bolted on tower section?
AL

[Gus]

EZ LOK thin wall solid inserts.

https://www.ezlok.com/inserts-for-metal ... /thin-wall

Gus

[Julian_Boolean]

I had inserts put in the ones of mine that I stripped, they had already been helicoiled, they were done by the ever helpful Chris at Grumpy 1260.

[chrisNI]

I think the J type heads seem to be a bit dodgier in the cam cap bolt region than the earlier ones. How much of that is to do with the erroneous torque setting in the manual and subsequent over enthusiastic fettling I don't know...

[LeeJackson]

Al,

No no cracks on the actual cap, Jair on the side of the webbing. So hopefully all is ok.. Now just hoping the new helicoils will hold ok

Cheers
Lee

[Al]

Photograph it well and in 1000 / 1500 miles when you go to check for tight clearances have a good look and compare.
Bloodied but not bowed! Looks like you may be OK after all.

Just by way of comparison here is another treatment of a similar situation.
http://www.kawasakimotorcycle.org/forum ... yself.html

And another
http://kzrider.com/forum/2-engine/49106 ... s-stripped

Next stop; chain jumping off exhaust cam sprocket, then,.. cant get cam cover down because chain too tight. The fun knows no end.


AL

[Al]

Photobucket is broken again! If youre making a frame for the camshafts / caps and have some spare material, one of these is handy. Quick to make too. Dimensions in the album http://s254.photobucket.com/user/zorded ... t=3&page=1



AL

[needaz1100r]

There is such a thing as a "bigsert", it's a timesert with a slightly larger OD, specifically to repair damaged threads where there is not enough material fo a normal timesert.

N.B. a standard timesert uses the same tap as a helicail or recoil, but is a solid insert - I much prefer them.

[swampy]

Ive got exactly the same problem with my elr head im thinking of big serts but the od of the m6 insert is 8.4 mm not sure if there will be enough wall thickness left between insert and shell. Only other options i can think of are get some 8mm ht slugs made, or weld and tap if that is a possibility.

[Gus]

https://www.ezlok.com/documents/pages/D ... Series.pdf

[zed1015]

Ive got exactly the same problem with my elr head im thinking of big serts but the od of the m6 insert is 8.4 mm not sure if there will be enough wall thickness left between insert and shell. Only other options i can think of are get some 8mm ht slugs made, or weld and tap if that is a possibility.

Another good option for a permanent fix is to fit studs.
M8 (or whatever you need in the head ) on one end and m6 on the other .
You have to watch the stud height once installed as anything much more than enough to get the nut and washer or nyloc on can cause the cam cover not to seat on its gasket.

[swampy]

Gus the prob with ezlok inserts is the o/d is 9.4mm and stands the a very good chance of breaking through the wall or pushing on the shells thereby distorting them.

[kev edwards]

Ive got exactly the same problem with my elr head im thinking of big serts but the od of the m6 insert is 8.4 mm not sure if there will be enough wall thickness left between insert and shell. Only other options i can think of are get some 8mm ht slugs made, or weld and tap if that is a possibility.

Another good option for a permanent fix is to fit studs.
M8 (or whatever you need in the head ) on one end and m6 on the other .
You have to watch the stud height once installed as anything much more than enough to get the nut and washer or nyloc on can cause the cam cover not to seat on its gasket.

I done this about 10 years ago, and the holes with the dowels i ground the tap slightly under 8mm to give a small shoulder for the dowels, i used very thin serated stainless washers and normal thickness nuts, this was not enough to allow the cover to go down properly so i took some material off of the inside of the cover above the nuts to allow for correct seating, the studs i made myself a few sets i gave away, if all 16 are done it's a bit of jiggle to get the cams in but not hard, the bike is still about, i also made up some 10mm inserts with the dowel as part of the insert for mr puffin on here and as far as i am aware his bike is still running with the dowels in it

[zed1015]

I done this about 10 years ago, and the holes with the dowels i ground the tap slightly under 8mm to give a small shoulder for the dowels, i used very thin serated stainless washers and normal thickness nuts, this was not enough to allow the cover to go down properly so i took some material off of the inside of the cover above the nuts to allow for correct seating, the studs i made myself a few sets i gave away, if all 16 are done it's a bit of jiggle to get the cams in but not hard, the bike is still about, i also made up some 10mm inserts with the dowel as part of the insert for mr puffin on here and as far as i am aware his bike is still running with the dowels in it

Yeah! done a few myself.
Spot faced the cover above the nuts for clearance.
There's a bit of variation with the inside heights of the covers and some don't need any alteration and some will even hit the stock bolt heads or caps with no gasket fitted.