If you have never accidentally over-torqued a bolt and stripped the aluminum engine block threads out of a hole, it'll almost make you puke when you feel the sickening give-way of a wrench when it breaks threads loose. Here are the threads that I unscrewed from the bolt when it came out:
Even worse, it was my new baby, 2014 new old stock DL1000, only 126 miles on it.
My bolt (M6 x 1) was stripped while I was tightening a bolt that uses an engine bolt on the left side lower cover, rear. It was for my SW Motech skid plate, which I like the looks of very much.
I did it, and as embarrassing and awful as it is, it can be fixed. I bought the Heli Coil set on Amazon for under $30 delivered and it's a few simple but **very** nerve-wracking steps....
1. Drill out the stripped hole to the appropriate depth. I measured it and put blue painters tape on my drill bit so I wouldn't over penetrate and stopped at the right depth.
fear scale of 1 to 10: about a 4
2. Tap the hole with the 1/4" tap tool. Only took about 5 minutes. Lubed the hole first. Went a turn and a half, backed it up a bit, turned some more. Sprayed out the bit with air a few times during this process.
Fear scale 1 to 10: 9.5
The thought of damaging these threads was echoing in my head. I was a first timer and always took wood shop over metal shop in high school. Wish I hadn't now..
3. Thread the helicoil into the new threads.
Fear scale 1 to 10: 2
No problem. It turned in with a little bit of friction, not much, because the thread coil is sprung a little bit and needs a tiny bit of compression.
4. Tap out the cross-bit at the end of the heli coil with the tool. It breaks off easily with a tap. Sprayed air in to be sure it was out.
New threads ready. Problem solved!!!
I'm ecstatic I got this done. It took me 2 nights of re-watching YouTube videos to get my brain ready.
It's all better now:
The left side cover is back on and the bolts are all on, only hand tightened. I'm waiting for my new torque wrench to show up. It's a 7-35 ft lb model with a digital converter on it for Newton Meters.
I think the torque spec is 9.6 N-m for these engine bolts.
Never again will I torque without the proper torque wrench....
Learn from my mistakes, any of you that are not seasoned wrenches and do not have the "feel" or the proper torquing measurement...
Best and Happy Holidays...