Motorcycle Repair: Oil change disaster, drain bolt, bolt hole

Question
I have an ‘84 nighthawk which I bought this season and, about to put it into storage for the winter, was changing the oil for the first time.  The crankcase drain bolt was very difficult to open.  After draining the oil, I noticed that there were some metal bits on the thread of the bolt.  It turns out that it does not fit back on – it reaches a point of resistance and then loses it.  I have no idea whether this can be fixed and how.  Meanwhile, I have a bike with no oil, sitting in my parking spot.  Help if you can!

Thank you.

Answer
Sorry to break the bad news but you will need to remove the oil pan and put a helicoil type insert as your drain bolt hole is stripped. In an emergency, you may be able to JB Weld it into place to get you on the road but then you'll have a mess getting it back off and then you'll need to drill it out, replace it, etc.

To remove the oil pan, you'll probably need to take the exhaust off:

http://www.bikebandit.com/houseofmotorcycles/showschematic/m9658sch401909

Here's the cover:

http://www.bikebandit.com/houseofmotorcycles/showschematic/m9658sch400589

You'll need a new gasket (#3). Be very careful when undoing the bolts. You don't want to strip a bolt down there.

Another possibility...

If you can lay the bike down on its side you may be able to tap out the hole and fit a larger bolt. Put an old tire down or some cushions. Remove the gas tank first.

Make sure you lump some very sticky grease or goo on the tap to get all the metal bits to stick to it and come back out. Some bits will stay in there but they'll sit in the pan - no harm.

If you think you can get the exhaust and pan out I would do it. If the bolts look rusty and likely to strip then I would look at tapping the hole from the outside and finding an oversize bolt.