So for giggles I just checked that bolt on my 701
30 mm bolt with 8.5 mm thread engagement
hole depth 42 mm but a 40 mm bolt runs out of threads
35 mm bolt works
if you pulled out the first 30 mm of threads I’m guessing a bottom tap down to 40 mm then
cutting a bolt to 39 would give you more threads then factory.
Being sarcastic as aluminum thread depth should be 2 x diameter. And I am actually impressed with you taking the time to measure. 6mm screw doesnt even thread 1.5 x diameter. So I guess to keep stock length screw an insert is the way to go.
See, now this is interesting. KTM did use bolts (screws? While are at it... Is it aluminum or aluminium?) that were too short! 🤣
EDIT
Sipping my coffee this morning and going down the rabbit hole looking at OEM parts to see if there are any KTM 6mmx35mm screws (so I can keep the neat torx/external hex configuration)... I have realized that I may have fucked up...
Note that there are three different screw specs for the cover... 3 and 5 are 25mm length (5 adds loctite)... 4 is a 30mm screw.
When I pulled it off, I kept track of 5 because I saw it in the torque sheet... Did not notice a difference in the rest.
I'm gonna bet I used a 25mm long screw when I needed the 30mm one
Now I feel like a dumbass. I'm my defense though, the torque chart in the manual didn't mention the 30mm long screw... There are 35mm long screws for the clutch slave cylinder though.
/EDIT
The #4 on the right side is my problem hole right now.
The most-right answer might be both a Heli-Coil repair on the buggered hole and a new set of 35mm screws/bolts for the cover (well, except the one that goes into the timing chain area).
Now I need to measure out whether I have to find some fully threaded 35mm long 6mm fasteners, or if the cover gives enough space for a partially threaded one ...