Aluminum Frame Thread Repair Z06, ZR1

Special Tools

CH-48106 Suspension Thread Repair Kit

Warning: Refer to Safety Glasses Warning in the Preface section.




1. The suspension thread repair procedure involves a solid, thin-walled, key-locking, stainless steel keysert. Use the keysert when the parent material of the original threaded insert is damaged.

Install the CH-48106-1 extracting tool (1) into the damaged wire insert.

2. Set the extracting tool by lightly tapping the tool with a mallet.
3. Remove the wire insert by turning the tool counterclockwise, while applying light forward pressure on the tool.



4. Use the CH-48106-2 12.8 mm drill bit to drill out the threads of the damaged hole. Drill to a minimum depth of 14.5 mm (3/8 in).



5. Use compressed air (1) to clean out any chips.




Note: The keysert will install more easily if you countersink the hole.

6. Use a CH-48106-3 chamfering tool or an oversize drill bit of 14.25 mm (3/8 in) to countersink the drilled-out hole.



7. Use compressed air (1) to clean out any chips.
8. Use CH-48106-8 cutting oil to lubricate the threads of the tap.
9. Install the CH-48106-6 tap socket or equivalent tool to the CH-48106-4 tap.



10. Use the CH-48106-4 M14-1.5 6H Tap (1) to tap new threads in the drilled hole. Tap the threads to a minimum depth of 13.5 mm (5/16 in).



11. Use compressed air (1) to clean out any chips.



12. Install the CH-48106-7 keysert into the slotted sections of the CH-48106-5 installation tool (1).



13. Use the CH-48106-5 installation tool to install the keysert in the tap hole slightly below the bottom of the countersunk surface (1).
14. Remove the CH-48106-5 installation tool from the keys. Rotate the tool so that the keys are aligned on the flat surface of the tool.

Note: The keys mechanically lock the keysert to the threaded parent material.




15. Use a mallet to strike the top of the CH-48106-5 installation tool (1) as necessary to drive the keys into the threaded parent material until the keys are even or slightly below the surface.



16. Inspect the keysert (1) for proper installation into the hole.

Note: If necessary, add shims or washers to the suspension bolt to check the torque and flushness of the bolt.

17. Temporarily install the suspension bolt, then tighten to 91 N·m (67 lb ft).
18. Verify that the suspension bolt is seated flush to the surface.