Any Tips or tricks on this repair -CRF's Only Forums (2024)

450man574 wrote:pull on the plastic while removing the bolt. after the bolt is out, heli coil the insert and it will be good as new

I have used helicoil on bolts that require +50lbs of torque - great stuff!!!

Been a while since I looked at a stock Honda tank. If it uses the 8mm hex bolt with the smaller thread (noticeably smaller than all the other 8mm bolts on the bike) you can just tap the hole to use the normal 8mm bolts. We have done this on aftermarket tanks alleviate the "special" bolt sizes. All we do is just run the tap, no drilling required. The larger shank bolt is less prone to cross-threading, and can always be helicoil'd if it gets stripped out.

Official Lurker

I didn't vote for him

2005 CRF450X

Try using some penetrating oil [ free-all is a good one ] first & let it soak down in. The shoulder is what is seized not the threads.

If things go really ugly you will end up spinning the nut plate in the plastic of the tank. the nut plate will get hot from spinning & pull out of the recessed boss/pocket of the tank. If that happens you will need to use your skills to remount that nut plate back into the tank. You can put it back in and us a soldering iron to melt the plastic back and / or use epoxy patch to remount.
It sounds bad but it works.

Use a little anti-seize on all those shroud bolts and go easy on tightening them down. Make sure a touch of the anti-seize is on the shoulder mating surface.

Good luck - it's fixable.

Easy fix.
1.Chuck up a socket in a drill
2.Spin the bolt as fast a possible.
3.At the same time pull out on the shroud.
4.The insert thats holding the bolt will melt out of the tank.
5.Remove the bolt from the now free insert with a wrench.
6.Clean the insert and epoxy it back into the tank.

The tank won't leak as the insert is in the middle of the plastic, make sure you have a bolt in the insert when you glue so the threaded hole doesn't fill with glue.

Here's a link to the sticky on here.

http://www.crfsonly.com/forum/viewtopic.php?t=13284url

Dale

I didn't vote for him

2005 CRF450X

I'm assuming the insert is spinning in the tank. In that case take a 1/4" drill bit and drill through the head--carefully just enough so the head comes off. Then you will most likely be able to turn the remaining stud off with your fingers. If not, you will be able to grab the insert and the remaining stud with pliers. This same thing happened to me. I used PRC which is a two part aircraft tank sealant to glue the insert so it wouldn't spin.

The thing about trying to bond the insert to the tank plastic is you need a glue that's at least as flexible as the tank plastic. PRC is sticky as hell and works great. Just make sure you are wearing something sacrificial when you mix the stuff up and apply it.

Here's a link where you can find some.

http://www.aircraftspruce.com/pages/cs/ ... /ac240.php

Wiljam wrote:The thing about trying to bond the insert to the tank plastic is you need a glue that's at least as flexible as the tank plastic. PRC is sticky as hell and works great. Just make sure you are wearing something sacrificial when you mix the stuff up and apply it.

Here's a link where you can find some.

http://www.aircraftspruce.com/pages/cs/ ... /ac240.php

Nice link.
For me the price would enter into the equation. I would try some JB Weld first.

You said the bolt is stripped, Usually what happens is the bolt freezes into the insert.Then when you try to take it out the insert spins in the plastic tank. Try the method suggested and if it is stripped as you think the bolt will spin and the shroud won't come off. Then we'll think of a different way to help you. But I'd bet money it is frozen.

Dale

dlpmx wrote:You said the bolt is stripped, Usually what happens is the bolt freezes into the insert.Then when you try to take it out the insert spins in the plastic tank. Try the method suggested and if it is stripped as you think the bolt will spin and the shroud won't come off. Then we'll think of a different way to help you. But I'd bet money it is frozen.

Dale

Dales got it: those darn inserts start spinning inside the tank and it feels as if the bolt is stripped in the insert (it isnt).

If you REALLY want that bolt, and that shroud, put an 8mm socket in a drill and a flat blade behind the shroud to 'press' it while your rotating the bolt. It melts out the plastic surrounding the insert (simply from kinetic friction), at which point you can pull it out. I did this, then wanted to use my oem tank for track (side note: it's cooler to rep the des tank at the track ), so I epoxy glued the insert back in the tank, making sure it sat flush. In retrospect, I would leave the oem shrouds on and just get new shrouds.