The last time I did an oil change I over cranked the threads (no torque wrench at that time) and after this oil change (two days ago) I noticed that there was oil dripping from the plug. I went under there today and tried to tighten it to 30 ft lbs, but it got slightly tight, then started to get looser (never a good feeling) I pulled the plug out, and the plug looks pretty good minus the fact it has chunks of threads on it. One thing I did notice while pulling the plug out, was that it was loose near where the plug was all the way in, but got tighter as it came out, then got loose again once it only had 1-2 threads left to come out.

I just did some searching and it looks like there are a few different options... but I am wondering what the best would be for my scenario. I read scooby's link in one of the threads where it talks about buying a repair kit (110-150 bucks!) and also read about a few trying to helicoil it (some said have to split cases which obviously would be preferred to NOT do)

Someone said they found a slightly longer bolt that reached up to the top threads (beyond where the stock plug reaches) and it is fine. I might try retapping it the same size (to clean up the threads) and then try a slightly longer bolt? Will running a longer bolt interfere with anything inside the engine? Isnt there a screen right above that hole? I dont want to cause any damage, so if anyone knows how long it could be that would be very helpful.

I also saw the rubber temporary plugs (well I guess they are supposed to be temp) where you put the rubber in, then put a bolt in the rubber to expand the rubber into the old threads, but it looked to me like it could be easily ripped out.

This really bites, because I JUST finished all of my mods and maintenance things for our upcoming dunes trip (june 3rd...) and now this happens.

Let me know what you guys think I should try first.
Thanks

 

Hey Roost,

I did the same thing a couple years back. I tapped it out to 3/4-16 threads, and havent had a problem since. If you lived closer to Richmond Illinois, Id take care of it for you. Just be carefull when you re-tap it, not to let any shavings get inside the cases.

Gary

 

Put some grease on the tap and the shavings will stick to the tap and not go in the motor.

 

ok, is that size a common size thread/plug? Did you just run a bolt, or an actual oil drain plug? (I am wondering about crush washers and finding one the proper length)

I got all the oil drained out and lifted it up to find that only 3/4 of the first thread, and the farthest thread to the top remain! (the area in between is actually SMOOTH)
I have tapped things out before, but might just consider letting a dealership do it.

 

I called my local shop which is actually a yammy shop but they are very nice to me and helpful because I dont care to go two either of the two hillbilly run bomb shops in my area. They said they could look at it for me, but said probably a helicoil is the way to go.

do most tap/die sets have a bit large enough to tap this out, or only specialty ones? I am just wondering how hard it will be to find a plug that will fit the new hole?

 

Roost,

I just used a bolt from the local hardware store. If the yammi shop will do it, thats great, but good luck finding a helicoil that size. The hardware stores will probably have a tap on the shelves good enough for that. How far from Richmond are you?

Gary

 

according to mapquest it is an hour and a half. (i tried just "richmond IL" first, then it came back and said "Richmond {Mchenry} IL" So im assuming you are in mchenry county? (there also popped up the option of richmond - tazewell, which looks to be around the springfield/bloomington area)

I was going to go out and around today trying to find a fix for this, thought I might try going to the hardware store to find a bolt that is like 2 mm's longer than the stock plug, to see if there are enough threads to securely hold the plug in. I am just worried that it wont be enough for a long term fix.

 

Roost.

Find a good industrial place, some auto dealerships might even have them in there fastener assortments, They are called Keenserts. Body shops also use these and another item called Karserts which act kinda like a rivet but are threaded in the middle. This type of thing are exactly what these are made for.

http://www.keensert.com/

I supply these to my industrial locations. I suggest these, They will not fall out!!

 

Roost check out the link below from the F650 web site

sump plug

 

ya that is the link i found in a search. I have tried all my local motorcycle shops and auto stores, along with farm and fleet/menards and two hardware stores. Nobody has a bolt that will fit (well one had one that was close, but I tried to put it in and jacked up the threads so much the stock plug wont even go in anymore)
I also couldnt find a tap or a helicoil kit big enough.

hmmm.