Cross threaded shroud bolt in fuel tank

[Jeeks]

So I was removing the plastics to thoroughly clean my 2000 250 and found that someone cross threaded one of the bolts to mount the shroud to the fuel tank.  The nutsert in the tank just spins.

Any ideas?

[KXcam22]

Jeeks,
 Bummer!  What you need to do is get the shround off so you can get get a grip on the insert.  Unless the shroud is one that you can destroy, best bet is to centerpunch and drill the bolt until just the head comes off.  Leave as much of the shaft as you can.  Then you might be able to get a grip on the insert with some needle nose vise-grip and twist the bolt out, or just pull the whole insert out.  You will likely have to replace the insert.  If it has been spinning you might need to glue in the new insert with a hot glue gun (or similar) or melted plastic weld so it doesnt spin.  Make sure you use antiseize on the new insert threads.  Hope this helps. Cam.

[Alpinestars2785]

This has happened to me twice on my 90 KX 250 and I've had to replace the tank both times, luckily I've found good deals so far, but now I'm careful and hardly ever remove the shrouds from the tank unless I HAVE to.  Good luck with your repair!

[KXcam22]

Again.  Always use anti-seize on those insert threads and they will live a long time. Cam.

[Jeeks]

I've only had this bike for a couple months, and I keep finding little aggrivating problems.  Nothing major, just little stuff like this.  Most of the hardware I have removed had silicone on the threads

[Hammer 4]

Jeeks, just be thankful it wasn't Red loctite...   And I hear ya re: the little aggrivating things..