Tricky M6 recessed hole Helicoil thread repair. BROKE A TAP! Can we save it?

How we repaired a tricky M6 thread in a recessed hole where an alignment pin goes, KZ900 generator cover. Broken tap, Helicoil thread repair on a CRITICAL hole!

[@ipfreelynow]

Tricky repair, well done. Not a fan of those chrome fins.

[@wa7215]

Good job Tom. 👍 I’m always a bit nervous, myself, whenever I have to re-Tap a thread into Alloy because as you know, it’s not very forgiving if you get a little too ham-fisted with feeding the Tap in. Which is why, I always like to err, on the side of caution, and only cut about a fifth of a turn of the Tap at a time, before giving it a bit more than that backwards to clear the dross, out of the thread, before proceeding forward again, always accompanied by lots of squirting of WD, and compressed air, as well, of course. Nice to see the KZ coming close to completion now. A damn fine looking bike, and a job well done by yourself. 😉👍

[@henryhawk978]

Nice job. Enjoyed the video and RIDE SAFE OUT THERE!

[@FREE_PUREBLOOD333]

Well rescued!!! Nice job. 🏍️💨🇬🇧👍

[@dbird29]

Dang aftermarket junk

[@TheDeanDalton]

Keep up the good work on my bike!

[@timlangley8926]

good stuff

[@paulas2610]

Well done fella. 👍 Stressful times when these things don’t go to plan. Who thought that threading into alloy was a good idea?

[@MotoRestoFL]

It’s worked for ages but when stuff sits and corrodes then dissimilar metals make nasty problems. Somebody broke that off previously for that reason.

[@dennytuma]

why was that dowel pin so important?

[@MotoRestoFL]

Aligns the stator mounted on the cover so it won’t hit the rotor. The rotor penetrates the stator on the cover. There is very little clearance. There’s two alignment pins, 180 degrees apart. Very typical setup in all sorts of assemblies.

[@qivarebil2149]

It(the threaded hole) could also have been cut open, and TIG welded - and then drilled and tapped. But then aain, You'd have to empty the cases... Lots of work, but You'd end up with essencially stock cases. Which is nice. 🤩

[@MotoRestoFL]

The cases are still stock cases. Just because a thread repair is done, doesn't mean the cases are no longer original. What, if you replace the 1973 battery, the one it came with from the factory or dealership when the battery wears out, does that mean the bike isn't stock anymore?

[@qivarebil2149]

@@MotoRestoFL Batteries are meant to be replaced. But the crank cases is a whole different story. Installing thread inserts means altering the cases, but replacing the battery, isn't changing the bike beyond point of no return. My point is, as long as it looks original and functions like designed to do, the bike is "stock" but not NOS stock. Anyway, You do marvellous work on the Kawasakis - keep them coming! 🤩👍