I've been trying to get mine going again after sitting for a while so I can ride it to work. I finally got it running again but it wouldnt idle. Plenty of spark so pulled the carby again, cleaned out the emulsion tube holes with a tiny hyperdermic needle and decided to do something about the semi stripped mounting thread. It has one of the original studs but the other has a bolt which was a concern as I wasnt able to tighten it as the thread seemed stripped. I could have just got a longer bolt and a nut but decided to do it properly.

I bought a M6X1 thread repair kit online for $60 posted. This contains a drill, tap, tapping handle/repair inserter, tab breaker and 15 thread inserts.


 I figured it is a very common size and I am likely to use it again. I bought an 8mm kit some years ago when my stepson got confused with torque wrench settings for the manifold of his old Toyota and stripped a thread in the head and I have used that one twice since.

For those not familiar with this repair I will go through it as it is very easy and within anyones capability. I will also add some photos after I take them. I've already done the repair but can show the general process.

First the hole is drilled out with the supplied drill that happens to be 1/4" for this size repair. Being aluminum with a sharp bit it goes through like a hot knife through butter so some care is needed. The hole is then tapped with the supplied tap and a little lube.  The supplied handle has a square hole which the tap fits. I just used WD40 but any oil would do. You turn it in a little then withdraw to clear the clips and relubricate and continue until complete.


 A repair insert is fitted to the special tool with the tab downwards and screwed into the newly threaded hole to the right depth. It is made of spring wire and so grips the hole.



 
Once at the right level (which happens to be exactly the thickness of the carby flange) the tab is snapped off and the repair is complete.


The hole now has a stainless steel thread which is much stronger than the original thread ever was.


The carbie was fitted to the bike and it idles nicely now so I think an air leak was likely. I had never bothered using propane or other sprays on it as I'd known for a while it needed fixing so am very happy it's now sorted. 



Last Edited By: 456eec Feb 13 12 6:30 PM. Edited 1 times.