This is putting a serious hold on my big brothers riding.. so if you think you can help,
please take the 2 minutes to type a reply. ANYTHING.

He just recently purchased a used 1992 KX500. It is in AWESOME shape,
but he did not see one problem.

The gear oil drain plug/bolt HOUSING has basically fallen apart in our hands when we went to
drain and refill. We suspect it was cased REALLY hard one time, and they had the whole thing
JB welded together so that the drain plug can screw in.
We can do the same thing, and JB it back together.. but it wont seal right, will leak,
and we will have to do the same thing over and over again every flush. We would like
a more permanent fix other than new cases. (he cannot afford that)

What if we drilled it out with a hole saw drill, (1 inch hole) and threaded the hole with new threads and used
a perfect sized very shallow bolt.

ANY help is appreciated. The season is coming.. and we want to ride together.

-Matt

 

What you suggested will probably work, but there may be unseen hairline cracks in the case that will split when you try to put in the new oversized plug. If you have enough room on the case to work with, I would drill out the damaged area as you had intended to do, but then weld another piece of material over the top of the case and drill and tap that piece for the new plug.

 

Agree, what he said, I dont know what material they made the case out of then, but try to identify before you weld, it will make a difference. PS. I wouldnt drill a 1 inch hole unless you are welding on new material. If are set on doing it your way, start as small as possible to acomplish what you need. The bigger the hole the harder to fill. 1 inch bolt is pretty big.