crosthreaded bolt

10 replies to this topic
  • skwerlee

Posted October 04, 2005 - 06:52 PM


the other day i accidentally cross threaded the banjo fitting for the oil return line on the right side engine case cover *the hard line that runs from the head to the case cover* does anyone know what size & thread pitch i will need to do a Hellicoil? thanks for the info.

  • grayracer513

Posted October 05, 2005 - 06:45 AM


No, not offhand, but to start with, that's a feed line, not a return. That particular bolt is different than the other two, at least on the '03 450. It should be a 10mm or 8mm ISO thread.

  • spinblue

Posted October 05, 2005 - 12:47 PM


You might be able to tap the hole with the current size to straighten the hole out. Sears Craftsman metric taps and a handle to turn it. If your near the NW suburbs of Chicago, let me know as I have them on hand.

  • matt116

Posted October 05, 2005 - 03:50 PM


You should put some grease on the tap, it will help collect the chips if you don't plan on takeing the head off the bike.

  • sirthumpalot

Posted October 05, 2005 - 06:49 PM


Be very careful if you work with the head on the bike. Any chips that stay in that oil line may likely end up in your cam bearings. :banghead:

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  • skwerlee

Posted October 07, 2005 - 09:27 PM


well the problem is on the banjo fitting on the right side case cover, no the head. I'm going to drill/tap/ & Helli coil it. I've done this before on another bolt, i just wanted to see if anyone new the bot & pitch info for the Helli coil

  • sirthumpalot

Posted October 08, 2005 - 04:36 AM


I don't know for that particular bolt, but take it with you to the parts store. Go to a store with lots of loose nuts/bolts and match one up to the bolt then check out what thread you have. Good luck!

  • Butta

Posted October 08, 2005 - 06:21 PM


I stripped that same bolt on my old 400. Luckily I had another side case/cover laying around from a granaded WR that I was able to swap out.

  • biznet1

Posted October 09, 2005 - 04:12 AM


Any hardware store will have a thread gauge. You can measure to get the OD.

  • rsstom

Posted October 09, 2005 - 10:30 AM


This bolt is a 10x1.25 The ones one the head and transmission are 8x1.25
Like sirthumpalot said, you'd better pull the cover to install the heli-coil. This oil line feeds the head and transmission so you don't want any obstructions there! Not for the price of a gasket!

  • skwerlee

Posted October 09, 2005 - 03:07 PM


thanks for the help guys, i really appreciate it. I'll pull the case cover off to do the work, i already have a spear gasket for reinstalling the cover. :banghead:

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