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My '03 RKC went to the dealer for it's first service. I noticed after the service that the Primary Drain Plug was screwed quite a ways into the case. Prior to the service there was about .330 " above the surface of the casting. After the service there is .070" above the surface of the casting.

The Service Manual says to use a dial caliper and tighten the plug until .160"-.180" is above the surface of the casting.

This is a brand new bike! Is there a potential to damage something internal by srewing in the plug too deep or did the dealer just screw up my outer primary cover?

I appreciate your words of wisdom this forum has really educated me in many ways.
 

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I do my own and tighten it in by 'feel'.... common sence prevails.
 

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It is a pipe plug thread (1/8") on it which means it is tapered. Not unusual to see them screwed in that much, however, if someone keeps doing it, eventually it won't tighten at all. I always use Thread sealant with teflon on them. Teflon tape works too. If that wasn't used at the dealer, the use of the thread sealant or tape will move it back out some.
Nothing internal will be damaged. I think I would mention it to the Service Manager at the dealer. He may need to be educated about it too. Lots of dealers use fairly inexperienced people for fluid changes.
 
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