previous owners hamfist spells trouble for I

[Dreadmanbastard]

hello, im new . im in need of a little advice if you would be so kind.
im just doing the first major service on my recently aquired r100. i have hit a small problem.

the bevel drive has a 2 filler plugs one for the bevel and one for the shaft. but on my machine the plug for the shaft has been rounded and is stuck in. it turns both directions continously . now at the mo thats ok cause at least its sealed but level of oil is unknown. if i use my cunning to remove said plug how (and heres the question) how does one reinstate the thread?? is it a simple die cutter or whatever they are called? and then ill need a plug to fit the new thread. oh dear please relive me of my sadness.

p.s i use my machine so cannot have it off the road for long periods.

thanks and praise

 

[Tarka]

Depends if just the male thread on the plug has gone....in which case just get a new plug and clean out the debris.
Or the female thread that it screws into has gone....in which case it looks like you`ll be needing to repair it with a Helicoil or Tymesert.

Hey..or maybe even both.

 

[Dreadmanbastard]

oh joy, having said i could get the rotter out im wondering if someone could offer any ideas. i was thinking drills and angry grinders but may be tempting major problems there.

 

[cookie]

if it's turning but not coming out, you'll need to turn and pull at the same time. might involve welding something to the bolt head. doesn't sound like an angle grinder will help.

when helicoiling drain plugs, be careful to get the insert in straight, or the head and washer will not sit flat, and it may leak.

 

[BillN]

hello, im new . im in need of a little advice if you would be so kind.
im just doing the first major service on my recently aquired r100. i have hit a small problem.

the bevel drive has a 2 filler plugs one for the bevel and one for the shaft. but on my machine the plug for the shaft has been rounded and is stuck in. it turns both directions continously . now at the mo thats ok cause at least its sealed but level of oil is unknown. if i use my cunning to remove said plug how (and heres the question) how does one reinstate the thread?? is it a simple die cutter or whatever they are called? and then ill need a plug to fit the new thread. oh dear please relive me of my sadness.

p.s i use my machine so cannot have it off the road for long periods.

thanks and praise

If you are referring to the filler plug - there should not be much pressure in there and I would think that you may, (could, would), get away with a tight fitting plastic bung - just knock it in - and replace as necessary when you change the oil, (not very often - a couple of plugs would probably see you out!!)

But as you suggest - tap it and put another bolt in - if you are going to leave the swing arm be careful of swarf getting into the swing arm - maybe do the work with the Bike on it's side - or get an "expert", (your local garage), to do it - only a few quid I would think

similar to this - or turn it upside down - as when you take a wheel off a push bike, (only joking!)

 

[Tarka]

oh joy, having said i could get the rotter out im wondering if someone could offer any ideas. i was thinking drills and angry grinders but may be tempting major problems there.

I think you`re asking how to get it out ? Yes ? Because it`s just turning?

If you get just under the hexagon head with a pair of wire cutters,they`ll close in under the head and grip the shaft of the plug.
You can then apply a levering action to put an upward force against the head and then if you keep that force constant you should be able to turn the plug out with a socket/box spanner/swivel head spanner,etc.

 

[DrFarkoff]

Tarka I had one of those a while back what a bollix it was the lowest thread of the drive seems to detach and wrap around the plug so pulling won't work as it still has threads on both bits and it won;t unscrew cost the thread is stuck in the first groove!

I removed the drive and worked at it for about half an hour to get it out and then helicoiled the filler hole and cleaned out the swarf and refitted

 

[Steptoe]

Be careful using a helicoil on the shaft drain plug.
It's not very thick so there isn't much area to tap into with a helicoil, which only work inserted deep . Plus you can't go too far inside due to the shaft.

 

[Tarka]

Be careful using a helicoil on the shaft drain plug.
It's not very thick so there isn't much area to tap into with a helicoil, which only work inserted deep . Plus you can't go too far inside due to the shaft.

True enuff Steppers.

P`raps best to tap it out to the next size and fit a suitable bolt to plug it.

 

[Ogmios]

dont know if this is a good idea or a terrible one;

long long ago...
i had an R80/7.
previous owner had done a few bodges on it - one was to cure the same problem you have.

his solution was to go UP in size by using an imperial size thread.

worked fine / but he at least told me as i bought the Bike - so no nasty suprise later.
i think it meant less 'meat' to cut into / therefore less damage

Good Luck.