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Repair instructions
Repairing damaged threads
A repair kit, 503 27 33-01, is available for repairing
damaged threads.
First drill out the hole using:
6.1 mm drill bit for magnesium crankcase
Then screw in the thread insert using a suitable
bolt and spanner.
Thread insert
A damaged thread can be repaired using a thread
insert. The slotted part of the thread insert is
screwed in first, as this is the cutting part.
To repair a thread that was originally designed for a
PL5 screw: first drill out with a 6.1 mm diameter
drill bit, then screw in the thread insert using a
suitable screw and spanner.
To repair a thread that was originally designed for a
MT6 screw: first drill out with a 7.1 mm diameter
drill bit, then screw in the thread insert using a
suitable screw and spanner.
This type of thread insert is best suited for use in
plastic and magnesium, but not for repairing
threads in aluminium. In that case use a helicoil
insert with metric screw.
New part no. Description
503 27 39-01 PL5
503 27 40-01 MT6
Guide bar bolts – replacement
1
Drain the oil tank.
2
Knock through the old guide bar bolt so that it falls
into the oil tank.
3
Remove the bolt from the oil tank.
4
Fasten a steel wire to the thread of the new bolt,
feed the steel wire into the oil tank and out through
the bolt hole in the crankcase.
5
Pull the steel wire until the bolt comes out through
its hole.
6
Pull through the bolt with its nut. Place a spacer
between the nut and crankcase.
7
Check that the square shoulder of the bolt is
correctly seated in the recess in the crankcase.
8
Refill with chain oil.