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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Latest bodge discovered
Post Info TOPIC: Latest bodge discovered
Dan-in-a-Van


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After my recent bit of green-laning I noticed my right boot had a bit of oil on it. Today I had a closer look at the bike to see where it had come from. I thought it was going to be the banjo coupling in the photo, but it turned out to be the allen screw below it. 

IMG_20180415_152142891.jpg

It looks like the screw had been glued in place with an oil ring under the head. I tried to screw the longest screw I had into the hole and it caught a thread but wouldn't tighten. I'm guessing a previous owner stripped the thread and then glued in a short bolt to keep the oil it :(

So, how long should the screw be? I'm thinking of getting a longer screw and seeing if there is a couple of good threads at the bottom of the hole. Failing that I'll tap the hole in the cover an fit an oversize bolt to stop the oil leak.  



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TTRfan


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Bad luck Dan.

It's not uncommon for the crankcase bolts to strip their thread and its an easy and permanent fix using a Helicoil or similar. Plus you can't then be accused of bodging by a future owner biggrin

I think the bolt is number 26 on the attached fiche diagram which is 56mm long.

Clutch and generator covers.jpg



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TerryK


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Helicoil is a much better fix than going oversize, there is some risk with going o/s as you have to drill the cover as well.

Terry

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Dan-in-a-Van


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I see there's another no.26 at the back of the casing. I'll spin that one out and use it to see if there is still a thread in there. If there isn't, I'll look into getting it heli-coiled when I get around to doing the valve stem seals.



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petenz


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if theres no thread at all..
run a 1/4" UNC tap straight into the hole..
1/4" is 6.4mm

worth a try..

i have fixed a striped 12mm drain pug with a 1/2" UNF
1/2" = 12.7mm

unfortunely 8mm & 5/16" don't work..



-- Edited by petenz on Tuesday 17th of April 2018 08:21:23 AM

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Dan-in-a-Van


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I found a +56mm long casing bolt in my "spares pile" and it turns out there is still a thread in the casing. I'm amazed the previous owner made the effort to glue in a short bolt rather than just getting one the right length :)

Thanks to ebay and me thinking the worst I am now also the proud owner of an unused heli-coil kit :0

Unfortunately after a little test ride it turns out it was the banjo leaking after all as well :(

The banjo was in really tight so I'm guessing one of the copper washers needs replacing. I couldn't get the banjo fully out with the exhaust in place. The exhaust studs looked like they haven't been removed for a while so I've left them soaking in Plus-Gas and I'll pull the exhaust and banjo off next weekend. :/



-- Edited by Dan-in-a-Van on Sunday 22nd of April 2018 09:20:03 PM

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