[Razorback1980]

CJ, take the banjo bolt with you to the local auto parts store. They will have a gauge that they screw the bolt into that will tell them the size and thread pitch. They will be happy to sell you a tap of the same size and pitch and you can take it home and try rethreading....meaning screw the new tap into the hole following the old thread pattern if you can using a little light weight oil. If you are uncertain, take the KLR off and take it with you to the parts store and if you go during the nonbusy part of the day, one of them will probably retap it for you.

If that doesn't work, then what you will have to do is take Jon's advice on the helicoil. You will then have to buy a helicoil tap and helicoil inserts and that will give you a drill size to drill the hole out to as Kevin outlined. Then run the helicoil tap into the hole (straight and following Kevins instructions of screw it in a little then back it out and keep it oiled) which will put new threads into your part. The threads will not be the right size you are looking for until you screw one of the helicoil inserts into the freshly made threads and then you will have new threads to screw your banjo bolt into. The helicoil kits I think are about 25 dollars. The new tap the size of your banjo bolts will be about five or six dollars. You will need to weigh that against the cost of a new part. The six dollar tap if done correctly will probably fix your problem if you still have threads in the bottom.