I’m back.  Can thread inserts be used in the crankcase where the engine cover bolts into (alternator side cover)?  I believe I’ve managed to screw one up.  When the good book says max 13m.m. - don’t try 14 n.m.

Thanks Zevenenergie.  That's a good tip!  I was also concerned about if there is enough material in the area to drill out a 1/4" hole to install the insert.  It looks like it, but things haven't exactly been going my way with this bike.

Any easier ideas than a thread insert?  JB-Weld Marine (works on aluminum).  Some red thread locker?  Just dope it up with some RTV real thick and oozing out?

It does happen to be the bolt next to where the leak from the gasket is.

The biggest problems I’ve had with Woody are things I done myself!  Argh!

Thanks for the spiritual enlightenment, philosophy, and free unsolicited psychiatry.  

There is a difference between maintenance and self-inflicted repairs.  I'm fine with basic maintenance, and I'm not in denial about how it is probably best repaired.  I raised the question, remember....

Just asking about other ideas.  Not a psychological evaluation.  I'm pretty aware of my personality defects.  I hope you are aware of how you are perceived by others.

On things that screw into aluminum that have very small threads....maybe it is best to use the torque at the lower end of the range - not the higher one!  When I tighten the side case bolts I use a 1/4" drive ratchet and one hand.....I just snug them up.  If the pieces are flat they don't need a lot of torque to hold them together.

Check and see how deep the hole is (as Zevenenergy mentioned).  Maybe you can use a longer screw.

Thanks guys.  To make matters worse, it seems the bolt snapped in the hole.  I can’t tell for sure.

I’ve never done a thread insert on an aluminum part (only in wood).  I’m trying to learn and understand how the thread insert is going to stay secured in the hole.

Thoughts on these?  The M10-1.5 external threads might be too big.  There isn’t a lot of material space diameter where my bolt hole is located.  And getting the hole straight and insert threaded straight and getting it flush with the engine case while the motor is in the frame sounds very intricate and tricky for a knob like me.  https://www.amazon.com/Z-Externally-Threaded-Stainless-Internal/dp/B002KVAWWI...

Thanks.  I saw these hellicoils and M6 kits.  You’re right.

I have an extractor set.  But can I get it down in the hole to remove the piece of bolt is the question.  And if I start tapping in the removal tool, what kind of further damage can I inflict upon myself!

I haven’t dug in yet.  Waiting on parts and then I’ll sit down and do everything at once.  I am dealing with my own “negative energy” about it right now.

Thanks.