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Author Topic: How to fix grab handle tank bolts on 690  (Read 396 times)

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Offline Amsterdam

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How to fix grab handle tank bolts on 690
« on: December 11, 2016, 04:57:28 pm »
I have a problem.  Well two actually as both 690s have this issue.  One of those threaded inserts into which you screw the grab handle (behind the seat, either side of the fuel cap) is spinning and I cannot fasten the bolt.  On the other bike the problem is worse as the bolt is and won't come out as the threaded insert spins in the plastic.  I am sure others must have faced this problem at some stage.  Anyone have a solution?
KTM 500 XCW, Husqvarna 701, KTM 1190 Adventure
 

Offline aka.Goliath

Re: How to fix grab handle tank bolts on 690
« Reply #1 on: December 11, 2016, 11:22:47 pm »
I had the same thing with my airbox cover. I'm not exactly sure this will work for you but I ended up - once the threaded insert was out - roughing up the plastic quite a bit and resetting it in with pratly steel.
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KTM 300 X-CW - 2012
KTM 530 EXC Rally - 2011 SOLD, KTM 690R - 2009 SOLD, BMW 1200GS 2009 SOLD
 

Offline Amsterdam

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Re: How to fix grab handle tank bolts on 690
« Reply #2 on: December 12, 2016, 06:38:12 am »
Thanks.  Anyone else have other ideas/solutions?
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Offline katana

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Re: How to fix grab handle tank bolts on 690
« Reply #3 on: December 12, 2016, 06:33:58 pm »
To get the one spinning inside, out:  Take a battery drill with a suitable bit.  Turn screw at a good speed to melt the plastic, while you apply a pulling force to the part that is currently screwed in.  Use a decent tool to loosen it thereafter and epoxy the thread part back into the plastic.  Use a anti-seize compound on the screws in future and don't over tighten.
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Offline Amsterdam

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Re: How to fix grab handle tank bolts on 690
« Reply #4 on: December 12, 2016, 06:54:33 pm »
Thanks, sounds like a good plan.
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Offline katana

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Re: How to fix grab handle tank bolts on 690
« Reply #5 on: December 12, 2016, 06:57:30 pm »
Thanks, sounds like a good plan.

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