Stripped Valve Cover Bolt
I did my 12K on my '03 last week, slowly following Paul's DVD's with the Clymer at hand. Everything went fine and I was relieved that things were not as complicated as I feared. That is - until I began to button things back up. As I torqued the bolts on the valve cover, I ran into one that wouldn't tighten. I removed it to find the threads filled with material from the head. Fortunately (I think), the bolt is one on the bottom, in the middle, so it may not be an immediate emergency. I know this bike had at least two previous owners, one or both of which had little mechanical ability. It is obvious that things were removed using improper tools (pliers instead of hex wrenches, for example). Anyone know if these can be tapped or some such? I know aluminum is tricky to work with, but I shudder to think of the cost for a new head.