Here's the thing. A while back I removed my head on my 00 929 due to a pair of bent valves. (CCT mishap)
After putting everything back together with the aide of a friend (you'll come to know why he's not much of a friend later). We come to the camshafts and putting them back on the head. While I go inside for a break, I leave him....very trusting to help me out and finish the install of the cam caps/holders and bolts that secure them down to the head. (Note: I had a manual through every step of the way)
While I trusted him to finish that portion of the rebuild (Him being an Automotive mechanic) I went in to clean up. Come back 45 mins later to notice him putting the valve cover back on. (SWEET, PROGRESS). Get everything back together....no issues.
Fast Forward >>>>>>>
About 2 months ago, I noticed my engine had been making more noise than usual and a drop in oil pressure. I thought the worst. I parked it (the same day) and left it alone for a while. Nabbed a new job, quickly became busy and left the bike sitting for over a month. Now....that month later, I begin taking things apart again. Just the top-end. Remove the Tank, Airbox, Valve cover. What do I notice?
One of the bolts that secures the holder to the head, is missing. Yes. Missing. Each cap/holder requires 8 bolts. I count 7. Im pissed. Research some more and find that not only the bolt missing could have caused the loud clattering/knocking but that also a bolt had backed out. After checking all the bolts with a torque wrench, I noticed one bolt kept turning. (the bolt had stripped the threads on the head - I presume to overtightening)
Summary 1: One bolt missing, one stripped, one bolt backed out due to undertightening. All on the same cam cap/holder.
So, that was the beginning of September. It's now 2 months later and the weather is getting gorgeous here in Austin, TX. I kick it into gear tonight and head out into my trusty garage and look at what I had started and never finished. I remove the cam cap that so faithfully kept in tact thru the Bolt ordeal, and pulled out my tap and die set.
Bulletin here: I noticed on Ron Ayers that 2 of the 8 bolts that hold the cap down, are LONGER than the other 6.
Part Number: 90017-MA6-000
Description: BOLT, FLG (6X45.5)
as opposed to
Part Number: 90019-MA6-000
Description: BOLT, FLG (6X39.5)
Difference in length are in BOLD
So, in essence I need to order 1 longer bolt.
Question: I am going to tap the hole out on the head. From what I can see the size/thread pitch of the original bolt is 6mmX1.00. For me to helicoil/timesert that hole, how big will I have to tap the head? 7mmX1.00? 8mmX1.00?
Someone with experience in this area please help. I want to get my bike up and running quick, but not quick enough to where I look something over. (Like what caused all this mess in the first place)
I have a Manual right here that I am borrowing, much thanks to Mavic here. I haven't forgot about ya man, just been busy with work. Haven't touched the bike in 2 months.
Here is what I am looking at with Ron Ayers: http://www.ronayers.com/fiche/200_03...inder_head.bmp
The bolts (#11) I need 1 of. That's the 45.5mm long bolt.