Case bolts loose. I'm punting.

My chain case cover bolts are not even coming close to staying torqued. I replaced my sprockets and chain and had to do a little cheating to get the cover to stay on about six months ago knowing it would be a problem later, so....

I ordered a engine bolt set for the scoot and tried the same trick since the cover started popping outward at the bottom when I'd use the clutch. New bolts old trick did not work. They're the same size bolts but now you can just shove them in so I'm hosed. I attempted tapping a more course thread in the case with some red thread lock and found myself stranded because the bolts backed out and the shifter came loose. I'm thinking heli-coil insert action. Any suggestions?

I attached a file with the offending areas of bolt failure for your viewing pleasure. The bolt next to the shifter has never been there.

The real piss off is I JUST installed fresh VM26's from WG because one my original carbs was not rebuild able (boogered mixture screw and I made it worse). I rode it for two weeks tweakin and tunin and it runs great! Now , it's back to sitting on the jack.

BTW WG does real good work. Dude seemed a trite busy but it's worth the wait. He's a straight shooter and does great work (I took em apart to see what I paid for and I was completely satisfied with his attention to detail.

Any thoughts on securing that side cover properly will be appreciated!!!!

I guess PDF attachments don't fly. The offending bolts are the two long ones towards the front of the chain cover that are the ones I'm having the most trouble with.

blue loc tite does wonders,id check all the other bolts including motor mounts at same time

Drill & tap for thread repair such as HELI-COIL, or an oversize bolt, other wise welding and re-threading the original size 6x1.0mm I believe. Any thing else will be a short lived repair. Make sure all of the bolts are there and will torque properly, also lube your clutch pivot arm.

I had the exact same problem on my bike. Helicoiled the 2 upper bolt holes and the 1 lower rear bolt hole to original 6x1 size. Drilled out lower front hole in sprocket cover to take an 8mm bolt, then installed an 8x1.25 helicoil in the lower front position in the crankcase. Very difficult to get a tap and drill in there STRAIGHT to do the job, so take your time. I got a long 8mm allen for the lower front hole at a metric fasteners store. Had to buy 5, it was like $5 or something like that.

-Dave

Yeah, that's what I figured. It is TOUGH to get a drill and tap in there. When I removed the broken bolts on the first run using an easy out was a real treat. Someone would make a killing making extensions for those things!

It seems things happen to the older scooters (prior owners, my screw ups,etc.) that simply need tending too. Its well worth it to me. I've also learned, ya gotsta check the torque on everything and typically apply blue loctite and re-torque stuff. When I first bought the bike the rear sprocket was about to fall off.

Thanks for all the feedback!!!

Right on ride on...

Jay

Hey Jay, click the link for a tap extension:http://www.mcmaster.com/#tap-extensions/=7o4fko They are not cheap, but probably cheaper than a new block.

I would personally try to order a heli-coil kit and fix those threads that way.

Instead of a tap extension, I used a tap chuck from Snap-On that can be used with regular ratchet extensions. FYI.

-Dave

remember to clean all grease and oil out of the threads before useing locktight it can lessen its effectivness. brake clean works very well for this purpose.

Well...

The two front side cover bolts were redone using 1/4 inch bolts /w heli-coils. Worked like a champ! The bolt closest to the shifter has become a major problem.

It seems like there has been some monkey business in the past and I cant tell what is what down there. A chunk is missing (about (3/4)out of the receiving side of the bolt on the case closest to the shifter. It also appears that the bolt may have been in to the case but I'm not sure.

My next move was to use a nut and bolt combo by removing some of the JB weld from the case which kinda worked but not to my satisfaction. I may have to JB weld the nut in there. DRAG! I did notice that once the cover was installed the clutch didn't feel right after basic adjustment on the worm gear. I pulled the cover off, put it in 1st and all was well. With the cover on it seems like the clutch is not completely disengaging. It seems like there's something missing. Is there supposed to be a sleeve that fits over the end of the clutch rod to snuggify the fit to the worm gear? It's been apart so long now I don't remember.

Thoughts? Thanks again for all the feedback so far!

Jay