KTM300, Stripped oil level screw - THE EASY WAY!

Stripped oil level indicator screw / bolt KTM 300 exc fixes including helicoil type insert without disassembly.

[@ValentinMaximenko]

I have the same problem and I chose the same decision %)

[@Abstract180]

Thbaks bud, this video just saved my Sunday!! 🤙 🇨🇦

[@oldmatesbackyard3510]

Hi Chuck, sounds to me like you're on the right track with your ideas. From what I've seen there is a small thickening of the engine casing around the hole so I would be careful about drilling too large a hole (which was why I selected the coil insert with the thinnest wall thickness). Good luck.

[@scotthibbert]

What about aluminum shavings made from drilling the hole? How did you prevent them from falling inside?

[@oldmatesbackyard3510]

Magnesium Alloy (which I believe is what the casing is made of) is very soft, certainly much softer than anything inside such as the gears therefore unlikely be able to damage anything. As such, I didn't worry too much about that, most of the shavings (almost all) will be drawn to the outside by the drill bit as long as you're not drilling in reverse, an extra precaution I took was to drain the oil after. I guess you could also flush oil in the top and have it drain at the bottom if you wanted to be even more cautious. Or, you could of course take the whole thing apart and do it that way or buy a new engine casing. I haven't had any issues subsequent to doing this fix myself.

[@scotthibbert]

Thanks for the replies. I’m going to try it on my KTM soon.

[@robertsrbell7811]

Grease on the drill bit and tap.

[@Michael_Douglas007]

Hey man - awesome video. I found myself in a similar frustrating scenario. The previous owner had already installed a helicoil in the oil level monitoring hole - but last time I removed this bolt the helicoil partially came out with it. Almost exactly one whole rotation of the helicoil came back out. What would you do? I’m gonna try to retrace the helicoil back in and lock it down with hardcore thread locker. But if it won’t happen for me, should I just get a new helicoil, and use the threads the original owner tapped into it? Or do I have to rebore the hole out and rethread it? Any advice is much appreciated 🙏

[@oldmatesbackyard3510]

Also, take care not to drill in any further than necessary, you don't want the hardened steel of your drill bit to come into contact with parts inside and, if you drill in deep you will be more likely to drop bits of drilled waste material inside.

[@jorgelsanchez4388]

Great job man.Thanks for sharing!