Ok, during my attempt to install the 951Max chips (
http://forums.pelicanparts.com/showthread.php?threadid=326838&highlight=banjo+bolt), the banjo bolt for the KLR box snapped in half when I was putting it back in the box.
Another pelican member was nice enough to ship me a replacement banjo bolt ad gratis. Once that was taken care of, I brought it down to my mechanic because I didn't want to mess up extracting a bolt. He got the remnants of the bolt out of the box with no problem.
I got the replacement bolt in the mail today. Went to install it... and sure enough, the inside threads on my KLR box are stripped just enough so that I can't even get the new bolt inside.
So what's my next step? Buy another KLR box and declare this "lesson learned"? Or is there a way to re-thread what needs re-threading?