To clarify: by jacked up, I mean cocked up, f-ed up, etc. It is not an issue of them being flush. The heli-coil threads are properly recessed into the case, just as the originals were. It seems as if the threads themselves are ever so slightly tilted, so that when screwed into place, the stud is not perfectly square vs. the case. Multiply that slight angle by 6 inches or so to the end of the stud, and it's 6 - 7mm out from where it should be. May as well be a mile, 'cause it doesn't line up with the cylinder. I will be discussing the issue with the machine shop, of course. I am concerned that it's not possible to repair a 2nd time, and that I'm looking at a new case, or a new engine. Ultimately that means this machine will be parted out and I am done with it.

This thread is why I take my bike to Ducati Seattle and write big checks.

This is a 1995 Monster with over 30k miles that has been rained on, snowed on, raced, crashed at 90 mph, dragged across the country and back on an open trailer twice, up and down the PCH twice, to the Dragon 3 times. I bought it new, and I have gotten my money's worth. Even if it was in perfect running condition, I'd be hard pressed to get 3k for it. Its not worth writing a big check to the stealership, and hasn't been for several years. If it were an 888, different story, but Monsters are a dime a dozen and will never be collectible.