Stubborn helicoil

I have been putting helicoils in my can cap holes since they are all stripped out only under my number one cap on my 1000. I got the rethreading right but the helicoil goes in at the very begining and stops turning. I burned out like 6 of these things just to get them to screw in and I rethread to make sure it is alright but the coils still jam. What could be wrong here. The threading tool came with the coils so I have the right tap. I wanna ride. O by the way. I got to ride the bike a week ago and the ride went down in disaster.

Are you using the tap that came with the kit? Sure sounds like a thread mismatch to me. I've installed hundreds of helicoils with no problem. Check your tap...

yeah its the one that came with the kit
But I have done helicoils before and it was fun untill now. I put the helicoil and the tap side by side to see if the threads will mesh and they are a little off, unless you stretch it or just mash it in alittle. I new this would solve my problem but it was never this hard!

The tap should be an "STI" tap. So if it is a 6mm thread it should read something like "6.0 x 1.0 STI". STI stands for screw thread inserts. You may try running the tap in the hole again to clean it out.

Could the Heli-coils themselves be incorrect? Manufacturers make mistakes too and maybe it got missed in quality control or shipping?

What does the installer tool look like? Does yours have a slot in the end or a tab?
i have 2 dif brands and 1 gives me headaches.the best 1 has a slot on the end for the coils tang to fit into. u can make 1 by slotting a drill bit.

When u install your cams use a longer threaded rod on 2 of the cap bolts.thread the rods in then use nuts to pull the cap down. the cap that pulls the lobe that is faceing toward the valve.
It is easy to stip the bolts on those things.

ok Fellas. I cleaned the threaded hole a bunch of times and nothing, it just sits there and clicks and threatens to break the tang off if I twist it anymore. The original bolts thread into the helicoil just fine, but the helicoil doesnt thread into the threaded hole. I like your idea Mark, but if I did something like that wouldn't I have to get a bolt that is bigger on one side now? Since I did use a bigger tap? I think I will go get a bolt that will fit the holes and see if the tap is wrong. Anymore suggestions?

i dont understand what u mean "I like your idea Mark, but if I did something like that wouldn't I have to get a bolt that is bigger on one side now? Since I did use a bigger tap? "
are u saying u tapped the hole to a larger size? my kz 900 uses 6mm. what does yours take and what size did u increase it to?

Sure sounds like you are trying to install 1/4-20 coils in a hole tapped for 6 mm.

Jay

the bolts are 6mm. i used a helicoil kit from autozone with insert tool, tap and coils included. The kit was for the 6mm bolts and i even tried it on the bolt before I bought it and it screwd on great. As for the tap or the threads created by the tap in the package, the helicoil nevr screws into the hole. Could there be a possibility of the wrong tap if when I put the threads of the coil and tap side by side and the threads dont mesh without really pushing the coil into the tap? Mark for your question I meant shouldn't the bolt now have a bigger side to screw into the now tapped hole while the other side of the bolt have a smaller diameter to fit into the small holes in the cam cap?

I would go down and get a new set, something is wrong, and its really not your job to figure out what it is, get a new set