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[hdguy1]

Went to change the plugs before a road trip and some threads came out with the spark plug on the rear cylinder. Dealer is putting a helicoil in and says it's a permanent fix. Anyone ever done this ? It'll be done tomorrow then off to California immediately, as my buddies all left Saturday.

Any thoughts on this ?

Thanks,

[Mr. Warlock]

Shouldn't be a problem, done everyday. They are a permanent fix. 

[D-N-D]

That is the correct way to repair and you will have no problems if done right.

[Aussie]

I have installed a few Helicoils over the years, they are as good if not better than the original threaded port for the spark plug, if done properly you will have no issues.
I would ask the person doing the job as to how they will control the swarf from falling into the cylinder whilst threading the port to fit the helicoil.

[dlaws01]

In addition to the repair, I would recommend using a spark plug thread anti-seize lubricant to help prevent the spark plugs from possibly damaging the other cylinder or locking up in the newly installed helicoil screw thread insert.  JMHO

[grc]

In addition to the repair, I would recommend using a spark plug thread anti-seize lubricant to help prevent the spark plugs from possibly damaging the other cylinder or locking up in the newly installed helicoil screw thread insert.  JMHO

     A light coat of high temp antiseize compound on the threads, and always use a torque wrench (15 ft-lb).  And of course always hand start with your fingers so you won't cross thread.  If more people would do it this way there would be way fewer thread repairs required.  Don't go crazy with the antiseize though.

Jerry

[hdguy1]

I have installed a few Helicoils over the years, they are as good if not better than the original threaded port for the spark plug, if done properly you will have no issues.
I would ask the person doing the job as to how they will control the swarf from falling into the cylinder whilst threading the port to fit the helicoil.

They have removed the head to do it so no danger of that.

Thanks

[hdguy1]

Thanks for your prompt replies. I was looking for re assurance that the helicoil was sufficient. Especially since I'm taking off immediately after I pick up the bike today.

P.S. The tech at the dealership also has to repair an exhaust stud as it broke during the dismantling of  the engine. I'm sure this has to do with the heat from these motors also. They said I couldn't claim warranty on the plug thread,  but I believe this would have happened to whoever removed the plugs. Me or them. Again I'm sure the heat of the motor baked them in there.

I might add the motor was rebuilt at 8,000 KM due to a faulty crank which caused massive overheating. Not to mention the clutch master cylinder giving up at 6,000 KM.  I'll see what the bill comes to but I'm going to take this up with Harley and see what they say. 

This has been a $37,000 nightmare. I'm not going down without a fight !Thank you all for your input. 

[Dan_Lockwood]

Thanks for your prompt replies. I was looking for re assurance that the helicoil was sufficient. Especially since I'm taking off immediately after I pick up the bike today.

P.S. The tech at the dealership also has to repair an exhaust stud as it broke during the dismantling of  the engine. I'm sure this has to do with the heat from these motors also. They said I couldn't claim warranty on the plug thread,  but I believe this would have happened to whoever removed the plugs. Me or them. Again I'm sure the heat of the motor baked them in there.

I might add the motor was rebuilt at 8,000 KM due to a faulty crank which caused massive overheating. Not to mention the clutch master cylinder giving up at 6,000 KM.  I'll see what the bill comes to but I'm going to take this up with Harley and see what they say. 

This has been a $37,000 nightmare. I'm not going down without a fight !Thank you all for your input. 

I've been using Heli-coils for over 45 years on everything from cycles, lawnmowers, outboards and snowmobiles.  I even used 11mm Heli-coil on my front spindle caliper mount on my Buick Park Ave.  Those cars would warp the rotors some many times that the caliper bolt hole finally stripped out.

Right or wrong, I've never pulled a head to do the repair.  On a two stroke I usually set the piston above the exhaust and intake ports and do the job.  Then I go in with an air hose, about a 5/32" to the top of the piston and blow around.  The only place for the chips to exit is the spark plug hole.  I then crank over the motor a few times with the plug out.  Coat the plug threads and install the spark plug.

On a four stroke there's even less areas that the chips would hurt anything.

Pulling the head to just install a Heli-coil is a bit much for me, but it is the safest way to do it.  I guess I just take more chances than others.

But in my defense, I do set the piston so the intake and exhaust valves are closed and then blow out the cylinder very well; followed up with a few revs without the spark plug installed.  This also lessens any consequential damage during the repair, like the broken exhaust stud.

Just thought I'd throw my thoughts out there.

I would not be afraid of the repair as now you're threading into spring steel that's fixed into the head.

Good luck on your trip.