Clutch cover bolt threads gone bad !! Urgent Help required

[shoeb2015]

Hello guys,
I have a passion + 2005

A mechanic over-tightened the bolts of clutch cover so much that it has lost threads,also one of the bolt broke halfway.
He somehow managed seal it by putting M-seal everywhere and got it back to me.

What can be done to fix the threads ?
Re-drill the threads as all threads have been vanished and has become almost smooth ?


Also,the bike is in horrible condition.It needs
1.New tires(Replaced today)(Rs.3500,MRF)
2.New gaskets
3.Brake shoes(95 front,110 rear)(Replaced today)
4.Indicators(95 rs each)(Replaced today)
5.Seat cover
6.Stickers and graphics
7.Speedo cable,and worm gear
8.Wiring repair.
9.New foot-pegs
10.crash guard has to be straighend
11.paint touchups
12.New swiches(195)(Replaced today)
13.Indicator relay,beeper.
14.Headlamp bulb.
15. Ignition switch,tanks cap(Lock set)(630)(Replaced today)
16.Engine oil(235)(Replaced today)
17.Clutch plates(328)(Replaced today)
18.steel plates(75)(Replaced today)
19.Clutch cover bolts(45)(Replaced today)
20.Kick pedal.(210)(Replaced today)
etc

UPDATE:
I went to a lathe shop today,
The threads were drilled and a new thread sleeve was screwed on the bigger drilled threads.
Stock size bolts now be used now.
Cost just Rs.50*3 threads =150.
Time 15 mins.
__________________

[Noor]

Query approved

[Guru_DTSi]

Since you are in Hyderabad, you might want to contact Probiker (Prabhakar). He might be able to help, since you are mostly doing the rest of the things yourself.

[Above_All]

You need to rethread them , the shop here do it in this manner first drill out the threads & then using a thread maker screw , makes threads to a bigger size than the stock & then uses bigger size bolt.

[shoeb2015]

UPDATE:
I went to a lathe shop,
The threads were drilled and a new thread sleeve was screwed on the bigger drilled threads.
Stock size bolts now be used now.
Cost Rs.50*3 threads =150.

[sibun]

My hero Honda joy has done 3 lacs km and even i have overhauled the engine twice. once by my mechanic and once by me. You have already solved the problem but here they drill the existing bolt and insert brass sleeve and rethread it to standard size.
Most of the thing you mentioned can be easily done.
Except engine overhauling my bike has every thing original even the lock set, indicators,wiring, paint, switches etc and you can see the photo in splendor ownership thread and still it looks like new.

[shoeb2015]

I also meant that they threaded back the sleeve to stock size.
I can now fix it myself if it happens again

[psr]

I also meant that they threaded back the sleeve to stock size.
I can now fix it myself if it happens again

Glad you got an easy cost effective fix ..
Best of luck.

[shoeb2015]

As you all know i recently got the threads fixed on my Passion.

Now the one of the threads have gone bad on my Dad's splendor too !!!(Magneto side)
Today While I was opening the magneto side cover I found out that the bolt was soo tight and after removing it there was some thread material on the bolt and when i tried to bolt it back , it kept spinning .

Reason For damage-
Previously mechanic over tightened the bolts while replacing the chain set.

I am considering to buy a torque wrench so that It can be used by anyone who is servicing it.(Me or my mechanic)

Any suggestions to prevent this from happening again ?
BTW whats the cost of torque wrench ?

[Pinaki]

Not much problem to lose one bolt on the magneto/front-sprocket cover . You can lathe it same as your passion, when your overhaul the engine later on .
Other than using some anti-seize grease (dunno where you get it here) on the threads when assembling and using a torque wrench there isn't much you can do to prevent steel bolts from de-threading aluminum threaded holes in such long durations . Other than the torque wrench , you'd need the full service manual too .. to know the correct torque values for each such nut .

[Vignesh vnktrmn]

Get the threads heat treated to make them harder.Using a painter's blowtorch to heat the threads and then allowing them to cool slowly will make them really hard.Do not use a high flame so that the heating is very slow and gradual.Get a skilled person to do it else you may end up melting it.