This is the first I've heard of Helicoil. So I searched it, watched a couple videos, and found a thread or two here where it seemed to solve the stripped thread problem (don't know if they experienced leaking). Assuming I have stripped internal threads:
1. Is the purpose of the Helicoil so you can reuse of the stock bolts? If so, why would you want to reuse the stock bolts if they are "dinky"?
2. Is there any benefit in using the Helicoil instead of just drilling/tapping to the next size up which, I would think, would get me a better/stronger bolt than those "dinky fasteners"? I already had to do this with the rear brake lever pinch bolt (previous owner overtightened it and stripped the internal threads). Tapping to a slight oversize worked fine for securing the brake lever but, then again, it's not being used to make a seal and keep oil inside. Does the Helicoil insert allow you to tighten more confidently (without the worry of stripping)? I found an opinion in one of the threads that there might not be enough metal for drilling/tapping...Has anyone confirmed this? But, if you're having to drill for the Helicoil...?
3. Does anyone make better/stronger/larger valve cover bolts to deal with what is starting to sound like a common problem? The sub-frame bolts were deficient, so there's an upgrade for that. The front brake reservoir Philips head screws get stripped out so Eagle Mike makes replacement hex-head screws. But, from looking at his website, it don't see anything for this problem.
For a failed Helicoil report, go to the advrider.com forum and search for KLR 650 Valve Cover bolt - New Threat! Has good pics of the fix (stud implantation). Hope I don't have to go to that extent.
My bike came with an old Clymer manual. When I get home, I'll look and see which edition it is.
Last edited by Schoen; 09-25-2019 at 09:49 PM.