radiator shroud insert problem.
Posted September 05, 2011 - 11:51 PM
after a really wet and muddy grasstrack on the weekend, i decided rather than just giving my bike the usual clean i would pull off all the plastics and get to those hard to reach places. Everything was going well until i started to remove the bolts to take off the right hand radiator shroud/fender (whatever) 3 of the 4 bolts came out fine, but the last was problematic. it seems as though the threaded insert in the side of the fuel tank has let go and is just spinning. i tried pulling the whole insert out with the bolt attached, tried spinning the whole shroud but couldnt get it out.
Any ideas to get the bolt and insert out? anyone had a similar problem?
Posted September 06, 2011 - 03:31 AM
Posted September 06, 2011 - 07:40 PM
The issue is 'dielectric corrosion': a steel bolt into a non-steel fastener (brass or aluminum).
The fastest way to fix it is to 'spin' the insert out, then JB weld it back in.
- Using a cordless drill on high, spin the bolt/tank insert until the plastic gets hot. Do not push.
- When the plastic starts to melt, remove the insert quickly.
- Diss-log the bolt from the insert.
- Clean out the recess left in the tank with brake cleaner
- mix up some JB weld and insert JB and insert into tank
- line up shrouds so the insert and bolt will go in and stay at the right angle and position. The JB will set up allowing you to do this.
- just before the JB gets hard, check it again for fit, and using a razor blase, clean off any excess JB.
Now, take off all of your dielectric potential bolts, and apply 'anti-sieze'.
Do the swingarm adjusters first, cause they are not as easily repairable if they seize in.
Do every bolt, or you will have this problem again, only worse................
Posted September 06, 2011 - 08:20 PM
Posted September 06, 2011 - 11:59 PM
Thanks again for your ideas