Free spinning final drive level plug bolt

[ChrisP]

I went to remove the final drive level check bolt, and it just spins and spins.  It's still held fast in the final drive case, but won't back out when spun.  Anyone encountered this?

[Bob_Roller]

Yes, the threads are stripped out .

[nhmaf]

It can be repaired with a timesert or helicoil type of repair.   It might be possible to fix if one goes very slowly, uses alot of grease on the drill bit to collect swarf, and carefully clean things out (flushing with gear oil) afterward.

[montmil]

Perhaps try to gently pull on the bolt as you attempt to remove it.

Several places on the bike where steel bolts thread into aluminum; offering multiple chances to strip the aluminum threads. Skip the manual's torque suggestions. Fork lower drain bolts are another location often stripped by ham-fisted POs.

I always blame the PO.

HeliCoil will get you squared away. Maybe use some red LokTite to help secure the 'coil' in the drive case. New crush washer and a short box-end to gently hand-snug up the bolt. Gently.

[Justin B.]

On the "Dawg" I made a threaded insert, drilled and tapped the housing, and fitted the insert into the case with JB-Weld.  I then used a SS cap-screw and copper washer as the new plug.

That was several years ago and still good...

[ChrisP]

Thanks ,all!
Totally going the helicoil route.