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Discussion Starter #1
I just finished replacing clutch plates/springs and when tightening the crankcase cover bolts I stripped a couple. They just kept turning!

I was easily able remove all the bolts but some are visibly twisted/stretched.

I can't see any thread damage to the crankcase bores.

I was using a torque wrench but I think the rubber oil seal was throwing it off because set at 7.5 ft/lbs it didn't click.

Is it possible just the bolts are damaged? Are these bolts be softer then the aluminum crankcase?

Does it seem reasonable to just replace these bolts with fresh allen bolts/blue lock-tite and hand torque?

Thanks once again guys!

T
 

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I don't see why you can't but I would first double checked to see if the crankcase is indeed still good. I was not so lucky with the front sprocket cover.:banghead
 

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i don't really recommend using a torque wrench (unless it's a GOOD inch pound unit) on bolts of that nature... almost every bolt on your bike should be mechanically snug and not much more, you can do it all by hand VERY easily. sometimes being too careful leads to problems.


as far as your bolt issue goes, you definitely pulled the threads out of the aluminum case... you may have to helicoil them to repair it.
 

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I've had issues like yours before, you can try running a tap dipped in oil down the holes, use light pressure on the tap. Use high pressure air to blow out the remaining debris. Use new bolts and slowly run them down till you feel pressure. Hand tight is best for these covers.
 

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I had an issue where i put the cover back on and thought the bolts were tight , however they started to back out on me one by one and thats when i started to use BLUE LOCKTITE on anything i take apart on this bike :twocents
 

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What is the range on your torque wrench? If you were using say a 0-100 lb-ft, then there is your issue. You never want to use a torque wrench within the upper or lower 10%-15% of it's range. (That is just what I have been told forever, and it has worked for me.) When you go past that point, you get to where the torque values are off. Another thing to think about is wether you have had the wrench calibrated recently or not. When I was a mechanic in the Navy working on jets, any time a torque wrench was dropped, it was re-calibrated. If your wrench cannot be adjusted, it will have to be replaced.

Personally, I wouldn't even use one on those. I have much better "feel" when it comes to turning those with a small ratchet or nut-driver than a bulky torque wrench. Now, axles, head bolts, things like that I will always use a torque wrench.


BTW According to the book, the clutch cover bolts take 9 lb-ft and the crankcase cover takes 17 lb-ft. Both with locking agent.
 

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Discussion Starter #7
I've got the bike all together now ready for my day at the track. The clutch cover bolt threads weren't damaged where they contact the crankcase, they were twisted on the top 11mm, where they travell through the cover. So I guess I was messed up the heads.

Everything went back together with new bolts, blue locktite and not so much force.

Once again thanks for everyone's imput. I wish I could contribute more.
 
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