XR650R Thread!

Discussion in 'Thumpers' started by JustinT, Nov 24, 2008.

  1. Toaliosis

    Toaliosis Adventurer

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    Very funny.
    I'm curious if the wrench idea will give a straight tap....
  2. hontri

    hontri Global Bummer!

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    I hate being defeated. If it were me i would cut the end off the tap using an angle head grinder with a cut off wheel then carefully grind a couple of flats on the now (shorter tap) to suit the open end wrench you will be using. But that's me:wink:
  3. Mur

    Mur Wheee!

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    I just went through the exact same thing you are going through, last week. It was only a semi-headache. :1drink lol.

    I used an open end wrench and it tapped just fine... I'm sure the steel heli coil will work alot better with steel bolts,not that I didn't smother them in anti seize,and drill a drain hole:deal Oh, and I used Red Loc-tite on the new heli coil threads I put in, just to make sure they didn't go anywhere. Something I read somewhere.
    Patience was key with this one.


    EDIT: I see the problem you're having,now. With the tap being too close to the swing arm...
  4. bill pierce

    bill pierce I don't wana pickle

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    The flats of that tap are right against the aluminum with the tap straight. As soon as it is turned 1/8 turn it won't be straight again. Don't think that's going to work.

    Some machine tool suppliers stock or can order you a "long tap" allows you to get into a hole like that. I have a few in standard sizes.
  5. ODSC1

    ODSC1 Been here awhile

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    Weld a short 1/4 drive extension on to the end of the tap. I had a tool like this made up at work to tap out the stock holes. Just used it again last week. Works perfect.


    Brian
  6. EduardoMas

    EduardoMas Spartan Overlander

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    In the 1st pic the hole seems off-centre. On the second pic it seems that the tap is crooked towards the arm at the shank side.

    If the square of the shank is not already ¼” or just under, use a grinder to take material off all four sides and then use a ¼” socket driver extension. You can get a cheap one and grind the OD if you need to.

    Put the extension on the tap and use a tap handle or even a wrench on the ¼” male side.


    When specifying inserts (at work) I only use helicoils for occasional use. For higher service I rather use Time Serts for repairs. Higher cost, but reliable in the long run. Then there are E-Z lok, great as an OEM choice, but they need more material to tap a larger thread.

    Good luck.
  7. EduardoMas

    EduardoMas Spartan Overlander

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    Hey Brian :-)
    I have your tools... will you make it to the Bike show in TO?
  8. ODSC1

    ODSC1 Been here awhile

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    Hi Eduardo!

    Won't be at the show this year. Leaving for Central America on Wednesday with the new XR(05) . Back at the end of January.
  9. EduardoMas

    EduardoMas Spartan Overlander

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    Just sent a PM at the ODSC with Garmin tracks from 2005 with some advice on how to follow it. If nothing else, it shows the beginning and end of some trails. Look at them on google maps and see if you find them useful.

    Enjoy the south!
  10. Toaliosis

    Toaliosis Adventurer

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    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>

    As I’m finding out the Helicoil taps aren’t “standard” sizes, I don’t believe a “long tap” exists for it.<o:p></o:p>
    <o:p></o:p>
    <o:p></o:p>

    I don’t have a welder but my buddy does…might have to take a trip to see him.<o:p></o:p>
    <o:p></o:p>
    <o:p></o:p>
    I just set the tap in the hole for picture purposed, I had begun tapping it yet hence why the tap appears to be cattywampus. The flat side of the tap is extremely close to the swing arm, I doubt grinding and then shaving down an extension would give me the clearance I need.<o:p></o:p>
    <o:p></o:p>
    Thanks everyone for their input. I’m going to try welding the extension on to the tap. I'll let you know how it works out.
  11. larryboy

    larryboy Chopper Rider

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    Don't do that, just throw it in the chop saw and cut the tap in half, grind some new flat spots into it until a 12 point socket fits, it'll be in the area where the axle goes then and a socket will clear.

    Wham, bam, thank you ma'am, all done.
  12. ride4fun562

    ride4fun562 Been here awhile

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    Women drive like shit and do not understand right of way, they would be completely usless if they did not have vaginas. That is all :becca
  13. medisyn

    medisyn Been here awhile

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    Is the XR ok? :cry
  14. ride4fun562

    ride4fun562 Been here awhile

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    Yea no crash just alot of close calls in a short amount of time. The mighty xr always carries me to safety
  15. medisyn

    medisyn Been here awhile

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    What area in CA do you live in?
  16. PeteN95

    PeteN95 Long timer

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    Hey, we agree!?!?! :rofl
  17. bump

    bump COLOR ME GONE

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    I bought some of the 3M flat black vinyl that they sell to sticker a whole car with for advertising. It has sun protection and everything in it already and I got plenty off eBay for cheap! It's tougher that paint and requires very little to get ready to apply - unlike the paint.

    My understanding is that Bob didn't use the HRC race piston as it came ever. I think Johnny said the bike tended to come out from underneath him... But they did sometimes use the HRC piston milled to use Chevron or Pemex Premium in some high desert races. I have one of the HRC pistons milled and all the instructions from the shop.

  18. ride4fun562

    ride4fun562 Been here awhile

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    Lakewood/ Long Beach
  19. sintax

    sintax Been here awhile

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    I second hearing this as well. I think there were different combinations used at different locations, but I know not everyone looked kindly upon the increased compression due to poor fuel options. I'd be curious to find out what the real seat of the pants difference is, obviously I would take anything JC said as pretty much Gods word... I'm guessing i'd compare myself closer to Helen Keller's riding ability, than JC's
  20. cragdweller

    cragdweller Adventurer

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    Any new info on the wide ratio gearset?