Stripped Final Drive Drain Threads

[Grumpy Goat]

Thanks for the input gents. Seems like the best long term move would be a time-sert, however, as I'm imagining it, that repair is going to be quite involved. Wheel off, remove the final drive, and probably even open up the case, yeah? Otherwise, even if you can clamp it into a vise, how will you prevent metal shavings from remaining in the oil and damaging the gears?

It'll be a repair that will outlast the motorcycle, and I'd never have to worry about over-tightening again, but yeah, ball park estimate for a shop to do it I'm guessing like $100 parts and 2.5 HR labor?

Considering all metal thread insert repair kits require drilling out the remaining threads, I'm thinking about just reinstalling the plug as carefully and securely as I can manage, and if I feel comfortable, test riding and monitoring for leaks. If it's holding for now, that can buy me some time to find the best repair plan asap.

If, as you said, the threads seem to be not stripped with the end thread broken off then if it were me, I would not be focused on damaging the remaining threads. I would be more interested in seeing how to flatten the sealing surface between the plug and the housing.

Your last paragraph makes sense to me. Its not like you have a choice if it is now being pressed into primary transportation duty.