Buy a helicoil kit. It contains a drill,tap,and stainless steel insert to renew the threads. You can buy it a napa.
good luck

I agree with using helicoil. I used on once to fix a spark plug threads.

I just had the exact same thing happen. A helicoil did the trick. If your nervous about doing it, bring it to any bike shop and they will do it for under a hundred bucks.

I am sure I could do it. I'm just worried about getting metal shavings in the engine

It's called gravity.....get under it, drill it, install your Helli...........You will have no worrys bout shavings in the oil............If your still wondering, you can buy a kit for a car.......it comes with a magnetized drainplug.......That way if you have any shavings, the Mag will hold onto them for you till you change the oil again...........Tim

Put a little bearing grease on the tap and then just just wipe out with a clean rag, and insert coil ! worked for me for years ! Capt Bob

Dont trust gravity or magnets. After you drill it out flush the crankcase with a little diesel. Not only will it flush the shavings but it will loosen up some of the sludge in and around the valves. I do it all the time in the tranny's on my dump trucks and I also run it through my PTO's.

Slick

I had the same problem. The original plug is metric, so I went to the next size plug in standard thread. A simple automotive drain plug. Drill and tap from an Autozone is all you need.

...both 'ya all are right...we filled the crankcase w/ diesel...get a couple monkeys to jump up and down on front bumper...then drain !!!...then use the magnets !!!...but,never did have a hole problem...best to turn back and forth to catch the thread...some guys are just too eager to get finished...cheers

I doubt a magnet will do any good on that bike , I had one of them bad boys that put me in the hospital for a couple of weeks ,if I remember right the engine case is a non-ferrous material , cast aluminum (pewter) I would say , a strong shop vac should get all the shavings out ,and you could have someone hold the vac right up against the case hole as you drill or you could probally get by with a rubber freeze out plug as I have seen bikes fixed like that before , it has a bolt thru the middle and a washer over the rubber plug , push it in the hole and tighten up , I'd drill and tap it the next size bigger plug from Napa, Car Quest or the Zone , it should be about 12mm

You will not get many shavings with the helicoil or if you decide to re tap it, when you tapping the hole use a little 3 in 1 oil and they will fall out, then flush it with some diesel it will be fine.

I guess you have never drilled through an engine case before???

1st of all the oil residue inside will SURELY collect shavings, so I suggest using a heavy grade axle or bearing grease on the drill bit and tap and turn it slowly as to not throw the metal into the engine when you break through...

2nd the cases are made of aluminum so the old magnetic drain plug trick is out of the window...

3rd after you finish drilling and tapping the hole before you insert the helicoil, flush the engine with deisel or some sort of varsol, or light fluid a few times...

4th after you finish with the plug and install it, run it for a few minutes, drain the oil and check the filter for metal shavings, if so keep re-filling and emptying till no metal...

I usually do 15-20 of these a year in my shop and thats the way I do it...only I use a time-sert instead of helicoil, it is a threaded sleve of metal instead of a wound up coil...e-mail me if you need help

chad, i realize this is probably a real busy time of year for ya, but do you also work on Honda dirt bikes? I have a little Honda XR 80 I bought for my nephews. I bought a motor for it off of ebay and it ran pretty good for about 2 weeks, but now I think the timing is off. It won't even start. If you kick on it a lot real fast it will eventually backfire. If you can fix it can you give me a ball park estimate and also, where is your shop?

U got mail...Fun..

I found a very easy fix. I went to NAPA, asked the guy behind the counter what he thought. I had a M12 plug that was stripped, he handed me an over sized M12 self tapping drain plug. It worked like a charm. Thank you NAPA man