Getting an 80' sg tomorrow...

[MPittma100]

Tap

Decided first thing before I took the U-Haul back, I was going to pull the plugs, and put the acetone/ATF mix down in there. Every plug came out pretty easily... EXCEPT number two. Threads were JACKED. I've had bad luck with tapping in the past...heli-coil?? Need some advice...so bummed!

There are spark plug hole taps/thread chasers available at auto parts stores. May try that first. 14mms is the size. Use grease on the tap to capture cuttings. Always use antisieze lubricant on aluminum head threaded holes/studs.

[Radioguylogs]

Yup

If the threads are that goofed up, probably the only choices are heli-coil or different head.

Therefore, there is nothing to lose by trying heli-coil if you control the chips.

Don't get stressed. The challenges are part of the fun if you have the right attitude. After the trials are overcome, the satisfaction is sweeter. When things get hard, just stop and think before doing something you are not sure about. The answer always comes quicker than you expect.

P.S. I see Mark Lew chimed in as I was writing this.

[Radioguylogs]

Oops

Big Oops! Mark Lew -> Mike P.

[ERM83]

If the threads are that goofed up, probably the only choices are heli-coil or different head.

Therefore, there is nothing to lose by trying heli-coil if you control the chips.

Don't get stressed. The challenges are part of the fun if you have the right attitude. After the trials are overcome, the satisfaction is sweeter. When things get hard, just stop and think before doing something you are not sure about. The answer always comes quicker than you expect.

P.S. I see Mark Lew chimed in as I was writing this.

I'm going to get a helicoil tomorrow...the top of the plug threads are COMPLETELY screwed, so I think the helicoil is the best option. Going to look into both for sure, but if the head is done for, then i'm RIGHT BACK to where I started with the SF. Haha, I'll tell you...I don't mind. Working on these keeps me out of trouble! Oh...ALL of those plugs were black as all get out. That worries me a bit...

[ERM83]

What type of grease should I use on the helicoil tap?? there's an o'reilly's here that's the ONLY location near me that I can snag a kit. I want to try to do this with ample time before work tomorrow...not trying to rush it, of course. don't work until 9pm, but my next day to work on it is Thursday; all day if I can swing it. again, i'll take some pictures, and post them. all of this help is appreciated beyond belief. my friends have actually been worried about me, because I work on these things too much. I CAN'T HELP IT! Once I start a project or try to solve a problem, I HAVE TO finish it. I'm like a degenerate mad scientist, minus the knowledge when it comes to these bikes.

Hey, Ray...the last plug I pulled out, I can't remember if I put the mix into that cylinder. will the others be okay?? I was in a hurry to get the U-Haul back, and I don't want to turn it over without that cylinder having the pre-lube (THAT'S WHAT SHE SAID...sorry...I had to). will the others be okay?? figured out the throttle problem...the carb springs are just...straight up seized, which i'll remedy, but isn't a problem being that i'm using the 79' carbs.

you all are AWESOME. SO GLAD to be welcomed into this forum. these bikes are my personal sanctuary at this point, working or not. I WILL get one (IF NOT BOTH) going before the riding season is over here. that is a PROMISE.

[ERM83]

ugghhh...I just realized that I repeated myself. NO MORE WORKING, MORE EATING AND SLEEP.

[CaptonZap]

Another method for keeping chips out of the combustion chamber when tapping the Helicoil is to turn the engine so that the piston is on the exhaust stroke, with the intake valve closed, and the exhaust valve open. Take a vacuum sweeper that has a blow function, and how ever you can, attach the hose to the exhaust pipe, so that air is being forced out of the spark plug hole.

Another brand of thread repair is called TimeSert.
http://www.timesert.com/
You might call around to engine machine shops and find one locally that could do the installation if you took the bike over to them, or one of the supply houses might rent you the tool set to get it done at your place.

CZ

[Radioguylogs]

Good Luck!

Another method for keeping chips out of the combustion chamber when tapping the Helicoil is to turn the engine so that the piston is on the exhaust stroke, with the intake valve closed, and the exhaust valve open. Take a vacuum sweeper that has a blow function, and how ever you can, attach the hose to the exhaust pipe, so that air is being forced out of the spark plug hole.


CZ

I had to tap one of my spark plug holes. I found this was great suggestion, but when I looked in the hole, the valves are in the way when they are open. A plug tap might go deep enough without hitting open valve.

I decided to close both valves. It left the piston at the top of the stroke, which made a nice landing spot for the shavings. I have a detailing attachments for my shop vac that I used with some tubing to vacuum out the cylinder after the deed.

If you put grease on the tap I it doesn't matter what kind- they are all sticky enough to hold the chips. My tap was just covered in thick oil and it gathered a surprising amount of the chips.

[ERM83]

before I head to work, I wanted to post some updates...I didn't tap the head yet, as I wanted to get the engine turning before putting that insert in. Just in case it comes out with the sparkplug. so, I did a few other things first...mainly got the carbs / air box off. before I put a pic up of the air box, here is the first disaster. blade-fuse "mod":



here's the air box (holy $#^&!):



Now i'm at a standstill though...fully charged, near brand new battery, and when I hooked it up, got NOTHING. no lights, no starter, not even a click. i'm not sure where to start with that. drained the oil that was in there, and it was nearly bone dry, and the stuff that did come out smelled like gas. I hope it's some fluke from it sitting forever. oh...i'm glad I have the 79' carbs, because the 80's are SHOT...completely frozen. i'll try to tap the head tomorrow, but definitely need help with the electrical issue first. I'll be damned if I don't get this thing going soon.

Eric

[TopCatGr58]

Hey Eric,

Yep, nice little rat's nest in the airbox, try not to breath in the dust when you clean it, Junta Virus possible exposure!

Okay, the 79 had the MAIN FUSE on the same side with the other fuses.
The starter button may be corroded/rusted, take it apart and check, clean.
You can take a jumper wire and connect it to the small soldered joint on the solenoid in your picture, should be blue/black wire, and other end to ground with key on, and if it gets the starter motor going, then the push button switch/wire/ground is fubared. If grounding the solenoid doesn't make the starter turn, then you can take a jumper cable jaw clamp and connect it to the two large cables/wires on the solenoid bypassing the solenoid and sending power directly to the starter. It should crank. If doesn't , then could be bad starter, or bad ground at starter and behind starter engine to frame ground strap. Also, don't forget to check the Emergency Kill switch.

T.C.

[DiverRay]

Starter is an easy fix, just pull and clean for the most part. The '80 MAIN fuse is on the OTHER SIDE of the frame, tucked in it's own holder. It SHOULD be replaced, as it suffers like all glass fuses.
Quick test of the starter: with the battery installed, just jump the two 10mm studs on the solenoid, upper left in your picture, and the starter should turn over. second way is just use jumper cables from your car, negative to engine bolt and tap the positive to the bottom bolt in the photo. Starter will turn if it's good.

[ERM83]

AWESOME, THANK YOU GUYS!! I didn't know that the main was on the other side...I thought it was weird that where the main is on the 80 had a 10 amp fuse???!?! I replaced ALL the fuses, minus the main. I've just pushed back some plans, because I HAVE TO go try all of this out. if I can get it to turn, i'm going to try to re-tap that spark plug thread. that one had to have a nest cleaned out of it as well, haha. man, getting that air box out was a PITA. not looking forward to putting it back in. haha.

[ERM83]

I meant a nest on top of the spark plug area!! haha.

[MaximPhil]

AWESOME, THANK YOU GUYS!! I didn't know that the main was on the other side...I thought it was weird that where the main is on the 80 had a 10 amp fuse???!?! .

Hi ERM83,
In case you did not know: The left side cover LOCKS on. you use the ignition key. look for the round cover facing forward underneath. A little WD40 or lock lube is a good idea if you have not had it off recently.
Phil

[TopCatGr58]

Hey Ray,

Thanks for the brain fart fix..I glanced at his Signature, saw 79SF, and went off of that, not remembering that it was a NEW 80SG to him! DOH!

And I meant to say Blue/White wire for the starter solenoid, but hopefully he figured I wasn't talking about the little RED one!

And you don't have to put the airbox back on, you can put pod filters on instead! YMMV

Good Luck!
T.C.