To start, no, this was definitely not me overtightening the intake manifold bolt. I bought this bike used (1999 FXDX), a previous owner installed the Screamin Eagle intake manifold before me and they utilized 2 hex bolts on the left side of the bike vs the factory allen bolts (which I know is a common thing to do).

This bike had an intake leak (possibly because of the problem bolt not being torqued properly), so, today I went to replace the intake seals.

One of those bolts came out harder than I would have liked. Went to install the manifold, creeping up slowly on all the bolts evenly (I know those bolts are only 16 ft lbs). I came no where close to the torque spec and it pulled the threads on that one bolt hole.

I'm thinking I can helicoil it with a stubby drill bit. I won't be able to fit a drill in there; would I be able to drill out by hand (small tapping wrench)? It will need a 5/16-18 helicoil.

If anyone has a better idea please let me know. I don't want to have to take the head off!

Picture attached

 

Looks like there's some good threads left down in the hole. You may be able to either use a longer bolt or use a stud and bottom it out when you install it. If there's enough room, use a flange nut on the stud to secure the intake manifold. I never use a torque wrench when installing an intake manifold. I snug up the fasteners nice and even and that's it.

 

They don't need to be torqued to 16 fp.. 8-10 is more than enough..