spinning gas tank insert

Huckster
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Huckster
Edited Date/Time 1/21/2012 1:48pm
any advice on how to get the shroud bolt out when the insert is spinning? I got the shroud off but cant get the bolt out. Its a 07 YZf if that makes any difference.

Thanks in advance.
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TerryK
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TerryK 4/11/2009 5:03pm
4/11/2009 5:03pm
That's a tough one. The last time I saw this happen there was no way to get it out.

One thing I do to prevent this is to put anti seize compound on any bolts that thread into insert in plastic.
lumpy790
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lumpy790 4/11/2009 5:16pm
4/11/2009 5:16pm
Its easier with the shroud still on but......Using a air gun spin it fast enough to melt the plastic while pulling it outward. When its out remove the bolt and run a tap threw it to clean it out then JB weld it back in. You will need to do this with the bolt sticking out the back side to make a pocket for the bolt to fit back in.
newmann
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newmann 4/11/2009 5:49pm
4/11/2009 5:49pm
What lumpy said, except being in the body shop business, we have all sorts of badass plastic repair materials to bond the insert back in. Lumpy must be a mechanic of some sort. They like the JB Weld!Smile
fcr
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fcr 4/11/2009 5:49pm
4/11/2009 5:49pm
lumpy790 wrote:
Its easier with the shroud still on but......Using a air gun spin it fast enough to melt the plastic while pulling it outward. When its out...
Its easier with the shroud still on but......Using a air gun spin it fast enough to melt the plastic while pulling it outward. When its out remove the bolt and run a tap threw it to clean it out then JB weld it back in. You will need to do this with the bolt sticking out the back side to make a pocket for the bolt to fit back in.
Good info.

The Shop

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lumpy790
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lumpy790 4/11/2009 6:41pm
4/11/2009 6:41pm
Had MC grease under my finger nails for 25 years.....till I started selling parts on line.
Huckster
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Huckster 4/12/2009 5:51am
4/12/2009 5:51am Edited Date/Time 4/16/2016 11:21pm
lumpy790 wrote:
Its easier with the shroud still on but......Using a air gun spin it fast enough to melt the plastic while pulling it outward. When its out...
Its easier with the shroud still on but......Using a air gun spin it fast enough to melt the plastic while pulling it outward. When its out remove the bolt and run a tap threw it to clean it out then JB weld it back in. You will need to do this with the bolt sticking out the back side to make a pocket for the bolt to fit back in.
tried that with a cordless drill, dont have access to an air gun, and it did not work. I also tried it with the shroud on and it pulled right through. The insert did start to come out a bit but it wont come all the way out. I am worried about ruining my tank. Should I just keep spinning it with the drill?

Thanks!!
newmann
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newmann 4/12/2009 7:18am
4/12/2009 7:18am
You need to make sure you have something under the screw so that you can pry outwards as the insert spins. Make sure you are not applying any pressure in towards the plastic tank, that would ruin the tank. Maybe try warming the plastic with a heat gun . Most inserts are not much larger than the hole they are in.
Huckster
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Huckster 4/12/2009 7:38am
4/12/2009 7:38am
whats the trick to prying it outwards as it spins? I tried pliers and a screw drive but when it spins they just dont hold.
jib-tmb
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jib-tmb 4/12/2009 7:49am
4/12/2009 7:49am
Can you get a fork like object behind it to pry with?
lumpy790
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lumpy790 4/12/2009 7:50am
4/12/2009 7:50am Edited Date/Time 4/12/2009 7:51am
Try having a friend slip 2 large flat screwdrivers under the head on both sides by the threaded part and apply enough pressure by prying to lift it while you spin the drill fast.
drmarkr
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drmarkr 4/12/2009 9:16am
4/12/2009 9:16am
On an 85 tank I did, I trimmed enough plastic out to get some beefy needle nose on it to hold it while i backed the bolt out. Did the same while I cleaned the threads up with a tap. Then filled all the gap I created with epoxy.

Anti-seize on the new bolt and it's still working fine.
bogdan912
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bogdan912 4/12/2009 4:27pm
4/12/2009 4:27pm
I got the shroud off and then with a hacksaw cut the head of the bolt off, then after I could get the metal insert that goes in the shroud off and unscrew the threads with my fingers.
Huckster
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Huckster 4/12/2009 5:45pm
4/12/2009 5:45pm
bogdan912 wrote:
I got the shroud off and then with a hacksaw cut the head of the bolt off, then after I could get the metal insert that...
I got the shroud off and then with a hacksaw cut the head of the bolt off, then after I could get the metal insert that goes in the shroud off and unscrew the threads with my fingers.
how were you able to unscrew the threads with your fingers if the insert was spinning?
bogdan912
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bogdan912 4/13/2009 6:10am
4/13/2009 6:10am
The insert only spins because the fitting for the rad shroud is really right against it... not because the threads are bottomed out, unless you put a longer screw in there. Once I got the head off the shroud fitting slid off and I was able to unscrew the rest of the threads very easily.
Holigan
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Holigan 4/13/2009 6:45am
4/13/2009 6:45am
Normally you can get them out by removing the panel (cut it around the screw if necessary), then drip superglue around the insert, let it dry and then soak the screw in WB40 overnight, they will normally come out OK.

To prevent it happening - Lightly greasing the bolt when you install them especially if you use strong detergent for washing the bike.

Jim Lewis - Merge Racing Technologies

Huckster
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Huckster 4/13/2009 7:25am
4/13/2009 7:25am
I got it out. I ended up cutting the head of the bolt off with a dremel and then screwing the rest of the threads out with vise grips. I had to stick a needle nose plier in between the insert to keep it from spinning, but it came out.

I put some JB weld in the gaps and am going to let that sit. Hopefully it will hold the insert in place. I also bought anti-seize and put it on every bolt that frequently comes in and out.

Thanks for all the help and suggestions.
lumpy790
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lumpy790 4/13/2009 10:10am
4/13/2009 10:10am
I have also melted plastic back it using a soldering gun. My gun came with a big flat tip for this type project.
jock
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jock 4/15/2009 4:48pm
4/15/2009 4:48pm
I had the same problem with a CR250 tank. After getting the insert and bolt out, I noticed
the tank had little cracks all over it. Picked up a tank on E-bay for $60 US.

Now on my 450, I do what Holigan says and lightly grease the bolts with Lanolin grease.
I have had no issues with the bolts coming loose after 16 months.
JYZ566
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JYZ566 4/15/2009 5:58pm
4/15/2009 5:58pm
Huckster wrote:
I got it out. I ended up cutting the head of the bolt off with a dremel and then screwing the rest of the threads out...
I got it out. I ended up cutting the head of the bolt off with a dremel and then screwing the rest of the threads out with vise grips. I had to stick a needle nose plier in between the insert to keep it from spinning, but it came out.

I put some JB weld in the gaps and am going to let that sit. Hopefully it will hold the insert in place. I also bought anti-seize and put it on every bolt that frequently comes in and out.

Thanks for all the help and suggestions.
Thats what I did on my 07 yzf, i used some anti sieze and less torque when I threaded the new bolt back in.

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