I've just noticed a steady drip of oil from the kickstarter spindle.
Is it an easy matter of removing the 5 cover bolts, heating the outer case until the bush drops out, replacing o-ring with new x-ring, pushing the bush back in (is a new one required/advised), and bolting up with new gasket?
If so, then I can probably handle that...
But any tips appreciated
You don't need to remove the…
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Mangled Allen screws
Managed to get 3 of the 5 allen screws out of the gearbox outer case but the heads of the 2 remaining ones are a bit mangled. I guess I'll need to file a key down a bit and try to insert it.
Any tips for dealing with such a situation?
BTW - I am using a 5mm key. Should it be an imperial one?
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Key size?
Surely the key should be imperial? Most likely 3/16". To help you get out of your dilemma, may I suggest a 'bodge' of hammering a torx bit into the mullered head and try undoing it that way? Usually pretty successful, but the torx bit will only be good for the bin afterwards.
Failing that, get hold of some 6mm 'left hand' drills (yes, they do exist) and drill the head off? Quite often it will start to undo long before the head comes away.
I'm sure there will be more suggestions soon,
George
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Mine has socket head screws…
Mine has socket head screws. Definitely not metric. Get the right one...it might fit deep enough to move. Allen keys should be snug...even tight...they are high precision
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Mixture of bolts
Getting a 3/16th Allen key certainly helped remove the remaining 2 bolts! It does appear that 3 have a 5mm head though, and all are various lengths. I don't have a thread gauge so can't tell if they are different, though to the naked eye they are the same.
The o-ring and bush didn't come off with the cover but were hanging loosely on the spline, and the bush can be pushed into the cover quite easily - should it be replaced or maybe just stuck in with some red loctite?
I guess I need a thread gauge and set of imperial taps in order to clean up the bolts and drillings now...
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1/4" - 26 TPI X 1 1/16"…
1/4" - 26 TPI X 1 1/16" UNDER HEAD SOCKET ALLEN SCREW BSF in effect with a 3/16" socket.
You will have nothing to lose by using red Loctite to take up the slack in the bush, even the green would do.
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Mixed bolts
Got round to measuring the bolts. Only 2 are the correct 1/4" linked to above. The others have a 5mm socket and are thinner and the threads are a bit mangled. I guess a previous owner just whacked in what he had to hand.
New correct bolts ordered, though I need to get a tap to tidy up the holes now. Amazing how these silly little jobs turn into an adventure... but a learning adventure which is the whole point I guess.
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Try correct bolts
Graeme,
Now you have identified the correct screws. The ones with 3/16 sockets.
Try screwing these into all the gearbox casing tapped holes.
Just as the metric 6mm screws deformed the thread, the correct screws will probably deform the threads back to correct. You will need the Allen key.
Using a tap to recut the threads can sometimes leave you with a very sloppy threaded hole, because of the aluminium you have taken away.
Peter
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One way around this dilemma…
One way around this dilemma is to turn and tap a grooved screw preferably a new one, buy one more than you need.
A Dremel cutting disc is used to cut a groove along the threaded section 180° apart on a slow spiral if you can.
Enter this bolt as far by hand as it wants to travel, once it "sticks" a slight tap/taps with a toffee hammer will help it along. Continue until the bolt bottoms out, then onto the next bruised threads.
Failing all of this advice within this forum rethread inserts are the best way to restore these fixing holes
Using the method described above you may find the use of "Loctite" red or green to take up the slack should you fel the need.
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M6 standard thread has 1mm…
M6 standard thread has 1mm pitch. That is 25.4 threads per inch. Because it is a smaller diameter (6mm) than 1/4" (6.35mm), it is not surprising that it can be forced to fit. A proper 1/4" x 26 this might well just go back in. It's not very highly loaded
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Resorted to mixed bolts
So I tried briefly to force them back to a 1/4" thread as suggested but that wasn't happening...
I reverted to what I had: 2 of the bolts are 1/4" and fasten easily, the other 3 are 6mm and also fasten perfectly and it actually looks like inserts have been used in these 3. See photo.
The seat for the kickstart bush is reasonably chewed up, but I put the new seal in and used loctite on the bush. All back together now and no immediate drip of oil. Time will tell.
Thanks for all suggestions - it's all quite a learning process!
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Please people the colour of…
Please people the colour of loctite isn't as important as the number! - the loctite website will guide you!
Dan
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You don't need to remove the bush to replace an o ring with x ring.
(My o ring and x ring are smaller than the recess. I don't know why. But I part filled the groove with silicone sealant first..and let it set after re-assembly)