TOPIC:

One of the screw holes on one of my float bowls has been stripped since I got the bike ('79 KZ750). I tapped that one with an American thread and it's held up fine, but now another one is stripped. 

Let's say I don't want to further sully my bike with any non-metric fasteners. Do I have any options? There's not a lot of material there to work with. I don't think there's room to put a helicoil in there. Don't think I can go up a whole metric size either.

Can these be filled, drilled and retapped? If so is this something I can do in the garage without welding equipment or will I have to take it to someone who knows what they're doing?

A helicoil doesn't take much space.  I've been messing around with some small 4-40 helicoils this afternoon and the amount of oversize from the original hole is minimal.

Any pics of the stripped screw hole?

No. I haven't pulled the carbs yet. Will probably do it this weekend.

I'm worried that the helicoil (or any thread repair) will weaken the flange on the carb body and end up causing more damage. Would love to hear from anyone who's had success with thread repair on a carb float bowl like this. 

Longer screw, nut & lock washer.  Not pretty, but it'll work.

Good Ridin'
slmjim & Z1BEBE

Here are some photos. I decided to take the easy way out and tap it with an American tap (8-32 i think)

Plenty of meat for a helicoil.

I'd say so.
Steve

Could it be brazed full, retapped with right size?

cbrianroll wrote: Could it be brazed full, retapped with right size?

No.  It's aluminum so brazing is not applicable.

Nessism wrote: Plenty of meat for a helicoil.

Good to know! I may give that a shot then.

Please excuse my ignorance,  why couldn't it be brazed solid? I've brazed aluminum tubing.(not very purdy lol)