big problem, decomp plug screw

ok, so somehow i stripped the screw that holds the decomp plug in. it is now gone, and the decomp plug wont stay in. will it be best to just drill and tap a slighty larger hole(that was my plan for today)? or what would you suggest? thanks for the help.

I had the same thing happen to me. I found a bigger screw that was a little to long and used my dremel to cut it to the correct length and then tapered the end so it would fit correctly. Then I used a tap that matched my new screw and tapped the hole with some new threads. The fix has been in place for about three weeks and seems to work fine.

awesome, ill try that.

There is only a few threads in there, so I'm surprised this doesn't happen more often.

I put a heli-coil in mine, so obviously there is enough material to drill and tap...

where can i get a heli-coil kit?

What I did, was tap the plug hole itself with a 1/4 inch pipe tap, and install a 1/4 threaded pipe plug with thread sealant. Looks good, works perfect and there is no way this will come out. You could then just fill the bolt hole with epoxy.

I bought a heli-coil kit to repair mine and it worked fine... although the kit is fairly pricey just to fix one hole. If you decide to go this route, just make sure that you dont thread the coil in too far otherwise you wont get the plug back in :D

And I figured I was the only one with this problem!

The Heli-coil is the preferred way to go for thread repair on the decomp plug retention screw. The screw is only supposed to be torqued to 5 ft/lbs and unless you have a good 1/4" drive torque wrench chances are you're going to over tighten it. I drilled the head of my screw and safety wired it to the mounting boss for the old decomp cable. If you don't safety wire it at least put a drop of red loctite on the threads.

i lost the screw, but i guess i can just get a new one instead of drill and tapping. but, what size heli-coil do i need, and where can i get it? thanks again for the help.

i lost the screw, but i guess i can just get a new one instead of drill and tapping. but, what size heli-coil do i need, and where can i get it? thanks again for the help.

A good auto parts store should have metric heli-coil kits, maybe not every Pep Boys etc., but they are fairly common and shouldn't be hard to find in your area. Call a fastener or bolt & screw shop.

Not sure about the size, maybe you should get the bolt first and then pick up the kit. Be warned, they can be kind of expensive, a lot more than you will pay for the bolt.

i lost the screw, but i guess i can just get a new one instead of drill and tapping. but, what size heli-coil do i need, and where can i get it? thanks again for the help.

I believe it is a 6mm x 1.0 thread but I'm 2000 miles away from my bike right now so please confirm the size before you get the kit. The 6mm x 1.0 Heli-Coil kit through McMaster Carr will run you about $40 and comes with 6 ea of 3 different length inserts.

Kind of spendy for 1 repair but the 6mm is a popular size so you should be able to recoup some of the cost from your friends. :D

Like he said^^^ M6x1.0mm.

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