Repairing more bad threads in the lower case! Poor previous repairs, making custom parts. Video #5.

VFR750F video #5, found more bad threads from a poor repair job inside the shifter assembly housing. Drilling, plunge milling and making a custom thread insert! Also, my theory on what ultimately caused the snap ring failure in the countershaft.

[@flexjay87]

This was a good solution, because it allows the threaded shaft to be used. Pure good luck ( and observation ) , that there is nothing in the case that the new sleeve would contact . And, as always, i learned something. Well done :)

[@owen368]

Had not seen the whole video when I posted previously but you have done a posh version of my idea basically.

[@MotoRestoFL]

Well, it may work but one would have to be quite precise. The major diameter of 6mm minus the minor diameter of M8 is roughly 1mm which is only .039 imperial, or a 32nd on a side. That’s awfully close. I did think of that but this way worked better.

[@owen368]

@@MotoRestoFL Think your way was better as the 1mm is not much wiggle room plus the slot/screwdriver issue would have been messy and awkward.

[@kghwanadoo]

I love that you switch from metric to imperial, it’s a dying art, I still might say 42” x 300mm it confuses the young ones! Lol. I’m mainly metric though in the UK. Nice work, bit screwed if you don’t have a mill, don’t know how else I’d have fixed that?

[@MotoRestoFL]

I was just saying that to the wife. There’s more too. Did three more holes today I previously missed same place for the cover. I shot what will be a prologue to video #6 coming soon. I use a metric scale sometimes but all my precision stuff is imperial. My Starrett 120 caliper is 45 years old. Cheers.

[@owen368]

Hope you don't mind but another option would have been plugging, basically drill and tap m8 then locktight m8 bolt in that been cut down and a slot cut in top to allow screwing in to case then drill tape m6 in that. Might be easier to drill and tap before fitting to hole Dad used to do that on engines where studs had got messed up. So could bolt in and cut head off after then tape and drill new thread obviouly not something you can do here as hole is in recess. Hence slot for screwdriver. Granted not the most gentlemanly way of doing things but have seen it done and it works.

[@xrv404]

Great videos you make. Is someone paying to get the engine rebuild or is it your own bike?

[@MotoRestoFL]

Thanks. The latter, I wanted a project bike that I intend to keep for awhile. Not a full engine rebuild, mind you, I just split the cases to change out tranny parts. I call this work a refreshing or resurrection, vs a restoration. Thanks for watching and commenting.