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Stripped threads on the swingarm filler cap...

Anyname

Active member
The previous owner was a pretty thorough guy and removed nearly every trace of the 12mm threads by over-tightening the plug. I have been using a rubber plug but plan to replace it with a 14mm plug from an airhead GS. Any wisdom from the group on this repair?
 
I helicoil them. It's a bit of a pain, since to do it right, you have to R&R the pinion shaft. This requires special tools and heat. Since it's such a pain, I usually do fill and drain threads at the same time.
 
I had originally planned to use a helicoil, but figured that taping for a helicoil would require at least as large a hole as tapping for a 14mm plug. The filler hole is fairly near the edge of the castin and I have some concerns that the casting might crack. I generally don't strip the filler or drain holes and figured that the helicoil's primary advantage would be a stronger thread.
 
what year and bike are you talking about? (i see a GS in your profile, but that bike is a Hexhead, not an Airhead. it likely makes a differemce.)
 
I had originally planned to use a helicoil, but figured that taping for a helicoil would require at least as large a hole as tapping for a 14mm plug. The filler hole is fairly near the edge of the castin and I have some concerns that the casting might crack. I generally don't strip the filler or drain holes and figured that the helicoil's primary advantage would be a stronger thread.

I got the machinist at work to do exactly that (tapping to a larger thread), works fine
 
I helicoil them. It's a bit of a pain, since to do it right, you have to R&R the pinion shaft. This requires special tools and heat. Since it's such a pain, I usually do fill and drain threads at the same time.
Lostboy is correct. To do the helicoil right, you have to get the pinion gear out of the way. I did mine half-assed and got the helicoil inserted in the half-cocked way that you almost inevitably will when trying to do it in situ. Result? Actually, not that bad. I added a couple washers and some Yamabond and the plug functions as a plug. If observers have poor eyesight, they don't even notice it.
 
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