First of all, I'm new to the forum and new to the atv scene in general. My dad recently bought a 94 300 4x4 that runs great. However, it started acting like the belt was slipping so I replaced it for him and it didn't fix the problem. Long story short,,, I bought the tool to pull the clutch and when I removed the clutch bolt,,, I found the problem. The threads are completely trashed on the bolt as well as in the crank!!! Looks like the PO (or shop) got carried away with an impact gun.

My question is, has anyone had the misfortune of being in this situation? If so, how did you repair it? I'm thinking that I can drill & use a time sert but would like some opinions before I screw it up even worse.

Any help would be greatly appreciated.

 

it must have been alot of force to strip the crank threads. it would be hard to drill the crank out. i would almost say a machine shop would a god bet.

 

Yea, I would think the bolt would break or strip before the crank. But, it looks as though both have stripped. I'll take a closer look tomorrow,,, ran out of time & patience today.

 

ya someone esle will have to answer on that one. let us know how u make out.

 

Get you a new bolt and a tap for the threads in the crank.Try the new bolt first if it doesnt thread in gently run the tap in and out a little at a time while useing a spray lube like WD40 through the tap.This should work.If not Permatex makes a product called From-A-thread that works if you follow the directions but only try it as a last resort to changing cranks.

 

ftwflh has the answer . That's what I'd do to .

Rick

 

Ok, here's what I found and did to fix it. Only the first 2 threads in the crank were damaged. So, I decided to drill them out. Found a bit that would just take out the tips of the threads and leave the bottom half intact. Drilled out the first 2 threads to get access to the good threads. Then I used my cutting wheel to cut off the damaged part of the original bolt. Found the tap that matched those threads,,, can't remember the size at the moment. Ran the tap into the crank about a quarter turn at a time and backed it out,,, blew out the shavings,,,, put more lube on the tap & crank,,, and went in another quarter turn. I did this until I got about a full turn with the tap, then lubed up the bolt, and ran it in until it got tight. Backed it out, blew out the shavings, lubed, and ran it in again. Now the crank threads look normal and so do the remaining bolt threads. So,,,, I think the problem is solved and I only lost a couple of crank threads.

Now I just need to find a replacement bolt and fix the starter,,, which btw was the second problem on the list.

Thanks to all that replied and I'll post up when I start reassembly to let you know how well the "fix" works.

 

glad it was a easy fix and cheap as well. i never use an impact to tighten the clutch bolt unless you can set it less then 50 ft lbs.

 

I have a bolt PM me

 

<div class="FTQUOTE"><begin quote>Originally posted by: ftwflh

I have a bolt PM me</end quote></div>


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