Screw Loose Dan

So, after my last update a lot has happened. The Helicoil didn’t work out, so after much thought and contemplation I decided to try a “Keensert”. It’s basically an insert that threads into a tapped hole creating a new tapped hole the proper diameter (basically the same idea as a Helicoil, but requires a bigger hole to be drilled). The main thing was to get the drilled hole as straight as I possibly could (with the engine in the bike). I started thinking about different jigs I could make when it dawned on my that I had a “spare” set of bad cylinders laying around. So, I took one to a local machine shop and had them turn it into a jig for me (basically cut it down height wise and made a drill bushing).

So, this past weekend I spent the entire time very slowly working my way through it. Drilled out the old hole, retapped it, and installed the Keensert. Installed all the studs on the rear cylinder. The stud was much straighter this time (not perfect, but I’m hoping close enough!). The stud didn’t seem as stable when “wiggling” it side-to-side as the others. I realize the stud probably doesn’t have a lot of lateral force applied, but I’m just not real confident it’s going to be reliable. After I got that together I bolted everything back up.

I have taken it for a short blast around the neighborhood and there’s no leaks…yet. I’m just not sure how long I have to go until I can trust it. But, for now I have her running.