Im so sorry to hear. Last weekend I spent 2 days takeing my time to put a new header on , only to find a oil drip the next day . I was ill. I wish I wouldve seen it before on the same day in which the pan was staring me in the face. I still havent repaired it yet. the headers were hard to seat even with both radiators out of the way. I used as recommended by yosh, a bungie cord to hook to the lowerhole in the main radiator to hook it to the front end of the bike to keep it out of the way while working. It was still digging into my knuckles at times and there was no room [ as yosh had said in the instructions that there would be] to have room to use a small rubber mallet to tap them slightly to make sure the flange and manifold had seated. I used new gaskets as well. Im really considering removeing the main radiator this time; instead of working around it in which I lost alot of time being carefull not to damage it. I just didnt want to deal with the antifreeze. but I will probually pull it when i do a fix. Too much loss time for me.
Dont feel pregnant tho,,I dont over tighten either; I very carefull to use the right rachet size and torcque to proper specs too. After my finding of the stripped pan sleeve, I did research with over whelming evidence that the busa pans were notorous for stripped out pan sleeves. If you notice at the end of the threading near the bolt head ; there is a small non threaded space for the crush washer to lay. I [out of charactor] went thru numerous oil changes without replaceing the crush washer in which it was pushed past that non threaded area and was slightly wrapped around the beginning of the pan bolt head. It is my opinion in my case since I dont over tighten and didnt use a new washer; that when the threading bottomed out it still wasnt quite tight enough; that that flat area enable to end and start pulling the threading out of the sleeve to my demise of not properly installing a new crush washer every time. Either or,There may be truth as well to a flaw in the design of the pan sleeve whicjh is aluminum instead of being made out of steel such as a timesert. Contact Goldenchild he gave me a steller price on a new pan. P.S My last bike was a V-max that had a nice heavy flat washer for a seal