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CrazyMotorcycleGuy
Most users ever online was 4,519, September 2, 2015 at 03:26 AM.
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  (#1)
Knee Draggin!
 
DemonRider's Avatar
 
Posts: 568
Join Date: September 30, 2002
Location: Tysons Corner
October 1, 2002, 11:03 PM

. . . get a cross threaded screw out of an aluminum frame?

Coleman Powersports gave me a complimentary cross-threaded screw for one of the side panels on my SV last time I took the bike in. :mad2: Snapped the head right off the next time I tried to remove the panel and now the body of the screw is stuck in my frame. I figure I\'d eventually take it to a shop to get it removed and have a helicoil put in, but will they be able to match the metric threads (assuming I can find a matching replacement screw)? If anyone knows an easy fix, let me know.


[Edited on 2/10/2002 by DemonRider]


Kal

'05 GSX-R 750
'01 SV650S
Full D&D, Dynojet Stage I kit:
Shimmed needles, 150 mains, 17.5 pilots, 2.5 turns
De-snorkelled & de-fendered
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AWOL
 
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Posts: 64
Join Date: February 3, 2003
Location: Herndon, VA
February 9, 2003, 11:53 PM

If any of the screw still remains proud of the frame, it should be fairly easy to remove. Snap-On make some particularly effective high grip/long handle pliers that usually do the job. Failing that, filing some flats in the remaining stub will provide enough purchase.

If the screw has broken off flush, and is large enough, you need drill down its center (take it slow and be accurate) and try to insert an Easy-Out type extractor. Problem with this on small screws is that the extractor usually can't handle the torque needed to extract the screw (DON"T SNAP IT OFF OR YOU'LL BE IN ALL SORTS OF HURT - trying to drill out a hardened steel extractor is almost impossible). Last resort is to drill the screw out completely. DO NOT try and do this in one go - first you need a good pilot hole down the center of the screw. Without this the drill will keep diving off the steel (harder) screw into the soft alloy frame making one hellofa mess. Use a final drill size large enough to clean out the old threads - this can usually be the drill required to start the Helicoil inserting process. Don't worry about Helicoil availbility - they make all common metric sizes. Now Helicoil away and you're in clover :thumbup:

Just noticed the date on the original post - hope someone helped this guy out before now!

[Edited on 10/2/2003 by CMSDyno]


Nick Jennett
Humble Tuner

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  (#3)
Knee Draggin!
 
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Posts: 568
Join Date: September 30, 2002
Location: Tysons Corner
February 11, 2003, 07:17 PM

Actually thanks, I hadn't really had any detailed advice. The screw wrung off flush with the frame so there is no way to grab it with a pair of pliers. I tried to drill it out with a small drill bit but the surface isn't flat and the bit kept sliding off. Any ideas on how to keep it centered? I probably should get a better drill bit too. Where can I find these Easy-Out extractors and can I do the Helicoil myself?


Kal

'05 GSX-R 750
'01 SV650S
Full D&D, Dynojet Stage I kit:
Shimmed needles, 150 mains, 17.5 pilots, 2.5 turns
De-snorkelled & de-fendered
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  (#4)
Ballaugh Bridge
 
CrazyMotorcycleGuy's Avatar
 
Posts: 6,871
Join Date: September 29, 2002
Location: VA
February 11, 2003, 09:43 PM

Quote:
Any ideas on how to keep it centered?
You need a center punch. About $3-4 at any hardware store. I just got one so I could safety wire the SV. Otherwise hardened bolts are a bitch.


'08 MARRC Expert Racer of the Year
2009 #3 Combined Overall Championship

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  (#5)
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Posts: 1,184
Join Date: October 5, 2002
February 13, 2003, 07:39 AM

Hey Travis,

How's the SV coming along? Are you going to make it to VIR on the 1st?


PAY UP LEE!

I've never had a lack of self confidence I wasn't sure I could overcome.
www.twodogsracing.net
WERA #521 CCS #521 '
03 R6 '00 R1 '02 R1 '04 R1 (coming February)
'02 GRC GP R1 Replica pocketbike (read monster)
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  (#6)
Ballaugh Bridge
 
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Join Date: September 29, 2002
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February 13, 2003, 08:48 AM

Quote:
Hey Travis,

How's the SV coming along? Are you going to make it to VIR on the 1st?
I'm expecting a fairing stay and manual cam chain tensioners in the next week. Once I get the bodywork fitted right and the frame slider holes cut properly I need to have it painted. I think I'll do some basic prepping of my VF500 too so I have a back-up bike if my SV were to break.

No trackdays for me though.


'08 MARRC Expert Racer of the Year
2009 #3 Combined Overall Championship

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February 13, 2003, 08:55 AM

Cool! You're welcome to our pits anytime you need tools or spares (Shaun has a Zuke). Will your first race be at Summit? Are you doing CCS or WERA or both?


PAY UP LEE!

I've never had a lack of self confidence I wasn't sure I could overcome.
www.twodogsracing.net
WERA #521 CCS #521 '
03 R6 '00 R1 '02 R1 '04 R1 (coming February)
'02 GRC GP R1 Replica pocketbike (read monster)
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  (#8)
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Join Date: September 29, 2002
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February 13, 2003, 09:12 AM

I'm racing CCS and cornerworking WERA. I'll mainly be racing at Summit and I may go to VIR if I can fit it in my schedule and I have the money.


'08 MARRC Expert Racer of the Year
2009 #3 Combined Overall Championship

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  (#9)
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Posts: 10
Join Date: November 20, 2003
Location: not canada, canada sucks
April 17, 2003, 03:48 AM

get a dremel with a tiny pointed stone bit for sanding stuff and put a little indentation in the surface deep enough for the tip of a small bit to catch
drill a small hole
either drill it out all the way
OR
you can epoxy bond an L shaped allen head driver in the hole,. but only stick it in a little bit so you can pull it out of it breaks, thats how i got sh*t out, no need to drill and helicoil

thats my 2 cents, im sure someone will discount the way i do things though!
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