Hi everyone! I have just done the second service on my 2003 XT 600e 4PT. The first time I did the service I noticed that the bolts holding the oil filter cover weak, ie as I tried to tighten them up I felt that melty feeling you get when a bolt/ or threads are about to strip. I left it a little looser than I would have liked, but after a while oil started to seep from the edge of the clutch cover. (Because the blots holding the oil filter cover are long and go right through and hold the clutch cover as well). These bolts are M6x80. I checked the depth, and there appeared to be a little extra depth in the hole, so I purchased some M6x90 bolts in the hopes that they would grab some fresh thread. It worked, with a washer or two. But now I have done another service and it looks like the threads in the engine casing are gonna strip. I have found bits of thread left behind in the thread of the bolt. I understand about overtightening and this isnt what I did. It needs to be tighter than I can get it to keep the gaskets all sealed up! WTF. Is there something that can be done? My first thought was to get it all open, clutch cover and all, drill out the holes and re-thread them to M8 and get some M8x 90's and trim them a bit. Has anyone done anything like this?

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Sounds like they are done for, you have to accept that you are going to be doing some engineering work!

I've used these in the past, and no need to remove the engine or take it to be Helicoil'd

Armstrong Precision Components, APC, Armacoil Global Partners

take the casing off and helicoil them......

Thanks for the response. I've never used helicoils before. On the bay they all are M6x1.0mm. Is this correct? they give a tap with the kit, so you are effectively tapping the hole bigger to allow for the helicoil to bring the hole back to M6 with new threads, yes? It doesnt look too difficult, but we'll see. I'm gonna leave it till the next service, and monitor it closely. Cheers

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Helicoil tip..

Only drill the hole as deep as you want the helicoil inserted.

Helicoils are ok but far from a perfect repair.

Is there enough "meat" to drill and tap to M8 ??

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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

I dont know, I've never had the clutch cover off. I will have to assess it when the time comes. The helicoil kits arent that expensive, and I could get a M8 tap from work, so which ever is the best shall be done. I do want it strong.

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Drill and tap will always be the strongest as long as there is enough meat.

You will have to drill out the cap too but again, no big deal.

If you cant get an M8 in there, look up "TIMESERT" inserts. They are much stronger and more permanent than helicoils.

Helicoils can't take a lot of torque, they often wind themselves out and i've found they chew up too on occassion. They will "do" though.

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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

If you know anyone with a mig or tig you could get them to fill the hole and start fresh.

probably way more work than you want to do but that would be the final solution...