well i stripped the oil pan today. whats my next move. http://www.gixxer.com/forums/images/graemlins/bash.gif http://www.gixxer.com/forums/images/graemlins/bash.gif

Order a new one! You can helicoil the old one if you are hard pressed to get it running. You will need to take it off, drill the threads out, then put in the helicoil and get a bolt to fit. I wouldn't trust this method for the long term. Order a new oil pan and a torque wrench.

thats what i figured, funny this is the first time i used a torque wrench and i f'ed it up.

I agree with the advice of helicoil or new pan. But......I stripped the threads on the pan on my '01 a few years ago. Saw oil dripping while I was on the road. Got to a hardware store. One dollar for a couple of slightly oversized self-tapping bolts. Oil-leak stopped. I kept my eye on it. Never so much as one drop on the bolt-head. That "fix" lasted perfectly for over a year when I sold the bike.

What kind of torque wrench? I think way too many people overtorque their drain plugs...just past snug is all you need.

helicoiling is a far stronger thread than the original the insert is made from hardened steel this method is used on many applications both in industry and on bikes and cars where high strength is required and is totally reliable !! . i have the helicoil kits for most metric sizes and have used them many times and have never had a problem also the helicoil kit should be cheaper than a new sump and you won't strip it again ..

let me say it was not the first time i used a torque wrench, just on my drain bolt. its a craftsman model 3/8 gose to about 85ft-lbs kinda long 16.5 ft-lbs came very quick with all that leverage. never had a problem with a regular 3/8 rachet. where can i find metric helicoils?? ron ayers has them for $97.00 and what kind of gasket sealer is required for the pan??

i think there will be a gasket on the oil pan you can also apply some silicone gasket sealer or any good branded liquid gasket ..not sure in the us..where you wold get a helicoiling kit i am in greece so sorry on that one ..can't help.. if you do the helicoiling properly the thread will be much stronger than the original thread which is good as the drain plug will be removed and refitted quite a lot i would think during the life of the bike. the most important thing is make sure when you retap the hole it has to be straight .. have you thought of taking the pan to your local machine shop they uaually do these sort of jobs cheaply maybe 20-30 dollars and they know what they are doing also you won't have to spend 100$ on a helicoil kit your only going to use once good luck ..