Norge Ground Problem

[Jerryd]

At the urging of several here, I removed the O2 Optimizer that came on my Norge. However, previous owner connected the ground wire of the Optimizer to the main chassis ground under the starter cover. Apparently in the process, partially he stripped the threads in the hole that the spacer bolt is threaded in to, and I cannot tighten it down enough. This spacer bolt not only connects the main ground leads but also receives one of the bolts that holds on the starter cover.

This is the second used Norge I bought with this problem. Has a fix come along over the years that I missed?

Thanks

Jerry

[rodekyll]

Any fix besides the obvious one?

[Jerryd]

Any fix besides the obvious one?

What would be the obvious one? Weld it to the case? Duct tape didn't seem to work

[atavar]

repair the threads?

[Jerryd]

The screw threads or the threaded hope in the case? It was a problem we ran in to when the Norge came out. If you over tighten it with the starter cover off or tighten the cover screw too much, that also over tightens it, the threads get damaged and the main ground connection becomes loose resulting in no starting or ECU hiccups! This is the second used Norge I've bought that had loose cables which couldn't be snugged down!

[PJPR01]

Could you put a threaded sleeve in there Jerry...and then screw in a slightly smaller bolt.  Alternatively, is there room to retap the existing hole, and then get a new bolt.

[Kiwi_Roy]

I just posted another topic on the main ground connection. it's absolutely vital to have it secure, if you can't connect it at the starter perhaps switch it to a gearbox bolt, better IMHO.

[tris]

Possible Options
a) Helicoil or similar
b) Drill and tap oversize
c) Clear drill through and use a nut both sides to secure

Access might be a problem for all of these though

[Jerryd]

Could you put a threaded sleeve in there Jerry...and then screw in a slightly smaller bolt.  Alternatively, is there room to retap the existing hole, and then get a new bolt.

I ordered a couple of stock bolts today from MPH. So, maybe I can drill it oversize and use an insert that will except the new bolt.

The thing to remember is that part is a male screw on one end which screws in to the case, and a hex head spacer that threaded on the other end to receives the upper starter cover bolt.

[pyoungbl]

OEM looks like this...this photo from my Stelvio:

I'd recommend moving the ground to one of the transmission bolts (and upgrade the ground cable to something heavier):

The ground wire is so critical that it makes sense to give it a strong path from battery to engine block.  At the same time you can benefit from a larger diameter ground connection.

Peter Y.

[Jerryd]

OEM looks like this...this photo from my Stelvio:

I'd recommend moving the ground to one of the transmission bolts (and upgrade the ground cable to something heavier):

The ground wire is so critical that it makes sense to give it a strong path from battery to engine block.  At the same time you can benefit from a larger diameter ground connection.

Peter Y.

Peter,

Thanks for the picture. The ground wire on the Norge appears to be the same size. There is also another connection at the same point with 2 cables. The 2 lugs under that bolt make it difficult to tighten resulting in stripping of the threads.

You're right about the importance of that ground. Something many have overlooked unless they had the starter cover off for some reason.

[Kiwi_Roy]

The ground wire is so critical that it makes sense to give it a strong path from battery to engine block.  At the same time you can benefit from a larger diameter ground connection.

Peter Y.

That's what I'm talking about
10x better in full view where you can inspect it now and then.

If you don't want to change the cable make an adapter plate to fit the large bolt with a small hole c/w nut and bolt to fit the existing lug, always grease the connection to stop it corroding.

[rodekyll]

That's what I'm talking about
10x better

ding!  DING! ding!

if it's not working there, put it somewhere better.  I always reroute my main ground to the bellhousing bolt near the timing hole and use a 6-ga ground cable.

fix the threaded hole any way you want at that point because it doesn't need to be beefy to hold up the starter cover --  maybe as simple as a dab of Loctite or jb weld.

[pyoungbl]

OK, beating a dead horse here....I cheated and had a new ground cable made up by MotoLectric http://www.motolectric.com/.  He will make a ground cable out of the stuff that is used for welding ground cables.  He uses lots of small diameter copper strands so the cable is very flexible and it's made to your exact length.  This eliminates any question of having a good ground.  You might have other electrical problems but not with the ground connection.

Peter Y.

[tris]

....

.....

So access isn't a problem - most things like this are a major PIA 

However on that back of this thread I think I'll pop the starter cover off my B11 and take a look.