However, when I came to replace the tank the long bolt on the bikes left hand side (generator side) was not playing ball and refused to line up properly in the captive boss on the frame and appeared to be cross threading.
For reference, I knew which side each bolt had come from as I like to always put the same bolts into nuts as they came off.
I had already partially mounted the tank on the right hand (clutch) side but not fully tightened the bolt, just screwed in enough to hold the tank in place.
In the end, I removed the tank and tried the bolt into the offending threaded boss 'on its own' and it still wanted to cross thread even with careful alignment.
I then tried the other bolt from the right hand side and this too wished to cross thread.
I also tried the 'offending' original bolt into the right hand side and it fit well so this does look like it is the threaded boss that is at fault here.
I did persevere with mounting the tank (starting from the left side this time) and did eventually, and with some patience, manage to get the bolt to screw into the boss without crossing / binding but I would like to try and fix this for the future.
My question is then, does anyone know the correct thread (and pitch) of these bolts so that I can try and obtain a suitably sized metric tap to try and rescue the captive boss thread?
ALternatively what are any other options that I might have should a tap not fix the issue?
Over the years I have had a lot of headaches with the blue plastic tank's mounting bolts. They try and cross thread for a pastime! I haven't a solution other than to lube the bolt and only try it by hand until you know its properly in its thread.
Have you found your answer on thread size? I am pretty sure its 6mm x 1.0. The bolts take a 10mm spanner so I doubt they would have a smaller diameter.
Over the years I have had a lot of headaches with the blue plastic tank's mounting bolts. They try and cross thread for a pastime! I haven't a solution other than to lube the bolt and only try it by hand until you know its properly in its thread.
Have you found your answer on thread size? I am pretty sure its 6mm x 1.0. The bolts take a 10mm spanner so I doubt they would have a smaller diameter.
Brian
Hi Brian,
Thanks for your reply. I had not heard from elsewhere concerning the thread size and as the thread is likely not of any special significance I would agree with your assumption of size. I can’t think of any reason to use a non standard size for this particular application although of course the bolts themselves have a longish thread less area presumably to aid location. I will look out for a suitable tap to run through the captive boss although there is no immediate hurry until I next remove the tank. I think I might invest in some thread gauges too if I can find something suitable but also relatively cheap.
It is also reassuring (if that is the correct phrase to describe it!) to hear that this is a common issue.
Yes, for me also it was a case of lubing and careful alignment by hand until the threads were properly aligned. A little bit awkward with the tank in place and hence I removed the already mounted side so that I could concentrate on the ‘dodgy’ side without restriction first. Patience paid off in the end though.
Sorry - I am still only half awake and hadn't made the connection with my old 350
TBH, there is such a small range of thread sizes used on the TTR that a thread gauge should be unnecessary unless you have the misfortune to also have an old Brit bike needing fettling in which case......
It is usually possible to check thread size and pitch by matching nuts and bolts to known existing ones.
Both well here thanks. Just returned from a trip to Anglesey in the funbus. Love Wales. Great scenery and friendly natives
To be fair I have thought about obtaining some thread gauges for sometime now. I no longer have old Brit bikes (sadly) but never say never. I am trying to better sort out my garage and yesterday I was sorting various tools etc. and trying to put them in seperate loactions for 'ease of access'. That all rather depends on if I can remember where I put them though. Found lots of A/F, BSF, BSW and BA tools that I still have plus lots of bits and bobs such as nuts bolts and some fittings from days gone by.
I have plenty of metric tools and sockets I have collected too but I have less in the way of 'hardware' as most of my bikes have been British and only one Suzuki Hustler apart from the 2003 Triumph I also have now which uses metric threads.
I really like Anglesey and North Wales too - used to have friends there as well as 'West Wales'. The friends in Anglesey used to say 'the day / night all the leaves went' almost annually due to its susceptibility to strong gales - if they are not gone already I suspect storm Agnes will see to that.
Hope you dont get too much affected today although it looks like my friends on the North coast will fare less well.
We are good too thankyou - still on the lookout for a 'fun bus' ourselves too.