Kawi2strokes.com Forum

Hello:

On the right cylinder one of the cylinder studs is stripped. The treads in the engine top case will not allow the cylinder stud to tighten down. When trying to tighten the cylinder stud down the stud just keeps turning. It is not grabbing. I took the stud out and the bottom 5 or 6 threads were filled with metal which I am guessing was the threads in the top engine case.

Any thoughts on how to fix?

Of course I put a new top end in, installed the cylinders and heads, and discovered this on the last cylinder head bolt. What a bummer! Pulled the right and center heads/cylinders off and new piston on right cylinder. This is where it currently sits waiting on a "fix it" method.

Any help/advise will be appreciated.

I'd think that a Helicoil or other thread repair insert would do the trick, but depending on the location and the exact shape of the casting in that spot it could be easy or difficult to do it without disassembling everything. Looking at an H2 case I have here, it might not be hard to do as-is, but if you break through when drilling and tapping for the insert, that would mean disassembly and thorough cleaning.

Also, if there's any chance of breaking through to a crank chamber in the spot you have to work in, one of the solid inserts like a Time-Sert would be preferable because it would easier to seal than a Helicoil.

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