tach cable / helicoil repair

[jiggersplat]

all,

i've got a oil leak coming from my tach cable.  i've tried putting some sealant on the mating surface but it's not doing the job.  the hole is pretty well stripped.  i think i'm going to try and repair it with a helicoil kit unless anyone has a better idea.  does anyone know what size that bolt happens to be?

thanks,
dan

[sledge]

My GS was leaking in the same when I got it, just one of many minor problems. I bought a replacement seal and retaining-ring from my dealer, fited it and it cured the the leak, they cost buttons. You can see the arrangement at this link courtesy of bike bandit.

http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view~schem_dept_id~703924~section_dept_id~1~section_dept_name~OEM+%28Stock%29+Parts~dept_type_id~2~model_dept_year~1995~model_dept_mfr~Suzuki~model_dept_id~703268~model_dept_name~GS500ES.asp

You need parts 18 and 19.

I cant remember the exact bolt size though although I think it was  M6, just take the bolt along with you when you go for the helicoil kit and get it to match, (dont forget the pitch as well as the diameter). I think helicoiling is the only viable option, you may be able to drill out the hole and retap it at M8 but without a careful examination I wouldnt like to say if I would try it. I think you will also have to remove the head to carry out the repair, you may find access is a problem due to frame-tubes, forks, exhaust pipes etc. To correctly fit a helicoil of this size you first need to drill out the hole and make it slightly oversize so it will accomodate the insert. For example for an M6 helicoil the hole first has to be opened out to 6.3mm (1/4") before retapping it. The kits come with full instructions that must be followed to the letter for satisfactory results.

[3imo]

I helicoiled mine when I first got her.

easier to remove the front end, exhaust and frame bar, than mess with the engine heads.

Your call.

post pics.  I woulda but didn't know about GSTWIN then.

Be extra careful, drilling out the hole!!!!!!!!!!!!!!!!!!!!!!!!!!!!

one good slip and she is dead in the water.

[jiggersplat]

thanks for the tips guys.  i guess i will try replacing that seal band first, though i don't think that is it.  and yeah, i kinda assumed that it would be a paint to get to it and that i would have to at a minimum pull the frame downtube.

dan

[Wrecent_Wryder]

3d