Sad day when the bike you picked up has stripped sparkplug holes(91 zephyr750)

There is no drilling involved, just tapping with the Time Sert tooling provided. 
Definantly want the valves closed in the cylinder you are working on.
 
You got to keep the valves and piston completely out of the line of fire!



 

I just can't resist.Ask the King of cobblers
What would Gepetto do ? 

Or Tarzans pal Cheeta with his tool of choice to fix anything 
 

Yep have to measure first how deep the tap need to go so not hitting the valve.

Spark plug threads are repairable in place.  Not the best choice for a bike that you want to lovingly maintain, but doable on a beater.

Grease the tap, to catch as many chips as possible.  You can also attach a hose on a shop vac, to chase any chips that fall off.  And besides, a few aluminum chips shouldn't hurt the engine anyway.  

For such a bike, I wouldn't spend the money on an expensive Timesert kit.  Amazon sells cheap china solid insert kits for $20.  No sense throwing good money away on a bike you are going to run into the ground...

Just tested if it is possible to have the exhaust valve open and if it is not 100% open it should work to use a vacumcleaner in the exhaustport.If you use compressed air when finished in the plughole combined with the vacum in exhaust it should work 99%.

It's just my opinion, but....

If you're going to do the job....do it right.  The condition of the engine should have little bearing on the quality of the repair.  Do the work as if you were a future purchaser admiring  the work done in the past.  That's what I try to do.

And no...I've never made money selling a bike that I bought to repair.  

I know they are. I have decide to not invest anymore money or tine into this bike. Just did the first oil change since I've had it since I haven't really be riding it and it hasn't been running until recently and was just sitting around. I knew it's been dripping oil very very slowly but I found out why. The God damn oil drain hole is stripped exactly like the sparkplug holes and the oil drain bolt won't tighten. So I don't think I will be doing much more to it. Might try to save up for a few months and order a whole new engine, or I might just try and sell it, and make a bit of the money I've put into it back in my pocket. Time will tell.

Buy the best for the least used on ebay, and buy American Made.

Then flip it!  You might get all your money back when the job is done, and someone else will benefit as well.

Call Nick:



These threads are perfect, but are easily made much better...

True and with how shits been going with it I don't want to spend that type of money on it anyways haha.

Don't want to make money on it I just want to get a little back. I bought it for 500 bucks bought some stuff for it and have put a little of my time into it. I know I'm not gunna make money from it haha I knew that when I bought it. It's just pissing me of and I feel like the guy that sold it to me ripped me off pretty good.

Like Nessim said a few aluminum chips isn't going to hurt it anyways. Aluminum is way softer than the pistons and the cylinders. It would just spit it out.

There's a butt load of 750 oil pans on ebay, if you don't mind doin a little gasket scraping...

But since it's a Zephyr, I'm a little less sure on that.



Good luck with your project, and remember these old Kaws love every bit of attention they can get!
Give what it wants, and you will be rewarded.