bugger ! oil level bolt stripped (well, case is !)

it has been threatening to go for the last while as it was getting , how shall i put it, sloppy in threads ? bit of play in it ? anyway, went to check oil tonight as i do after every ride and or weekly.. tightened it up and bugger..wouldnt tighten so removed to find threads in bolt... so, questions....

can i just remove and have it tapped out and new bolt ? (without too much carnage ?)

or is there another fix for this as i reckon its common...anyway, let me know...ps, can i fit one with a oil level in it if i change it from 05 bike to newer model with glass level in it ?

whats the best way to go with this P.I.T.A !

I have an 07 TE 450 and put a 7602 cover on with a little glass window to see the oil level. little bling on the bike and it is very well made( fit was perfect, stronger than the OEM part, and looks great). check their web page and see if they make the same for a 510 '05. If I ever figure out how to post a picture I would for you.

its the same engine afaik so hopefully will fit.... just the cash thing ant time as i have a big ride this week and need it fixed one way or the other !!!

ah ,just looked at it... the glass is in the clutch cover.. i would need to have check hole welded up...not a bad idea i don't think....? its a crappy design and flawed anyway..high maintenance bike with a check hole thread that is alloy and wears badly..not a good combo ! lol....

just thinking.. i think i will get the hole welded up and then when i can force myself, i will buy a 7602 case with glass inspection window in it ! ..i think i will go with that !

i would like a red one but need to find/hide some cash from the wife to buy it lol.. how much post to OZ ? ps, will weld it up, got jb weld/ chemical metal in it now with old bolt but not too happy with that.. i'd rather it was smooth and looking nice.. its ok and looks normal as i cleaned it all up aferwards but i know its there and thats worse..it will niggle me as i am a fickle bugger ! LOL..

Rabskyline,
I've got a 04 te450 and I'm sure I'll be in the same boat soon. Everytime I check the oil I'm worried it will strip and ruin my day. It has to be a common problem with our bikes.

Maybe Santa will bring us both 7602 clutch covers.

I stripped the check screw on my 07 TE 450. Funny it was at the same time I put on the 7602 cover. Turns out one last check was once too many. I used "Quick Steel" (the two part epoxy) It has held up great. Been over a year and a half and a few thousand miles since the fix. The 7602 cover is still in great shape too. They haven't been the easiest miles either...

I took the cover off and drilled and tapped to a larger size, mine was helicoiled by the dealer after the 2004 recall on the kicker! so after me checking the oil several times the helicoil pulled out. I picked a bolt out of the bin found the tap and a drill and fixed it better then new.

yeah its a crappy design and the only thing about taking the size out is that there is very little meat left for the bolt...i have mine all sorted up now but as soon as i can, i will put a 7602 case on it with the inspection glass....and sunline levers, and stator cover and new trick gear selector and all the other bits of bling i have on my HUGE santa list !