[AP Guy]

Well as the title says I was changing the oil in my just over a week old bike tonight and the threads came with the plug. I am trying to stay calm but I am raging on the inside. I just got the bike not more than a week ago from the dealer. Its used so I guarantee the dealer will say sorry, nothing we can do. THEY were the last to change oil in it this last fall, they told me that when I bought it. I put a little over 100 miles on it and wanted to change the oil since it is the oil that has been sitting all winter. That being said, I didnt put any oil back in it. The plug is back in but I could tell it wasn't going to snug up. If I go any further it will be completely stripped.

SO...my question is how hard is it to drop the oil pan. I am an aircraft mechanic by day so I feel I am mechanically inclined and wondering if I can just drop the pan and put a heli-coil in it? Has anyone done this before? Also is there anywhere that has a pdf file of the service manual?

Bike is a 2005, all stock. just shy of 8k miles.

I am wanting to ride this thing over the 4th...by birthday is on the 3rd. If I cant ride this thing for my birthday Im not going to be a happy camper.

Heres a pic of the threads:

 

[underdog]

My so did this on a old (then brand new) Honda Oddessy of mine. We were headed out for a week so needless to say... I was in a hurry. I drained all the oil, stood it up so the oil ran away from the plug threads, put a little release agent on the threads of the plug and some kind of aluminum type JB weld or whatever (I got it from work) in the hole and on the plug. Screwed it in and went riding after it dried and I put the oil back in. Crappy fix but it worked for 5 years and then I sold it.
It might be worth a try if you are headed out for that ride this weekend.

 

[kawtoy_77]

I would go with the helicoil. I did a spark plug hole my '77 kz1000 with the head on the bike. There is a trick to everything but it can be done easily.

 

[BennyV]

+1 Helicoil.

 

[AP Guy]

Sounds good, I'll stop by the hardware store or auto parts place and pick one up. I am not one to half *** anything. Especially when it involves something that keeps your oil in. The plug would hardly tighten up, and with the engine at operating temp and all the metal expanded who knows how well it will hold.

Anyone know what size and pitch the threads are on the drain plug?

 

[JSharp]

12mm and I believe 1.5mm thread pitch. You've got the plug out, take it with you when you go to pick up the helicoil.

If you use some grease or anti-seize on the drill and the tap when you open up the hole for the helicoil it should catch the big chips. You can flush the rest out with light oil.

 

[So-Crates]

Just a suggestion, but if you are going to drop the oil pan to install a helicoil, why not just replace the oil pan altogether? I mean, if you arent one to half-*** it...that would be the full-on fix, right??

Ive used helicoils in the past - I know they work....but for something like the drain plug that holds in the life blood of your engine - I would replace the oil pan if it were me.

Just saying....

 

[JSharp]

I'll take steel threads over aluminum any day. I'd trust a properly installed helicoil more than the aluminum pan threads. The threads in the aluminum will be larger when he's done installing the insert and they'll get no wear from the plug being removed to do oil changes.

 

[kawtoy_77]

the helicoil in my big bore KZ1000 spark plug hole seems to hold over 120psi, and combustion heat just fine.... i don't think an unpressurized oil pan is that big of a deal.

Helicoil is like 10-15 bucks, available at local hardware stores, and a new pan would have to be ordered. The pan retails for $150, and would take a week to get here.

AP_Guy
I would tell the dealership about it, and just see what they say.... probably no dice, but you don't know till you ask!

Helicoil +1

 

[zephyrboy738]

I use to work at a motorcycle shop and we would put helicoil in the head when someone would strip the spark plug hole. If they work there they will work anywhere.

 

[AP Guy]

When I say I dont like to cut corners I am also on a budget. We use heli-coils at work when spark plug holes get worn out on engine cylinders(sparks plugs get taken off and reinstalled every 100 hours) and they hold up fine.

I couldnt not find a 14M-1.5 helicoil kit anywhere. I've got a 14-1.25 coming from a local parts store but silly me forgot my plug at home today and after looking at it I think 14mm is a bit large. looks more like a 12mm. Ive got the pan down, was very easy to do. I will clean it up at work tomorrow and hopefully find the right heli-coil and get this thing going. Got a pan gasket ordered, should be here thursday or friday.

Does anyone know for sure the plug size?

 

[kawtoy_77]

That I do not know.....

 

[JSharp]

I use to work at a motorcycle shop and we would put helicoil in the head when someone would strip the spark plug hole. If they work there they will work anywhere.

Back in the 70's the heads for Yamaha 2 cycle road racers came with helicoils installed from the factory. You were constantly reading plugs on those things to get the jetting right so they might be in an out a dozen times on a weekend. I never had one cause a problem.

 

[JSharp]

When I say I dont like to cut corners I am also on a budget. We use heli-coils at work when spark plug holes get worn out on engine cylinders(sparks plugs get taken off and reinstalled every 100 hours) and they hold up fine.

I couldnt not find a 14M-1.5 helicoil kit anywhere. I've got a 14-1.25 coming from a local parts store but silly me forgot my plug at home today and after looking at it I think 14mm is a bit large. looks more like a 12mm. Ive got the pan down, was very easy to do. I will clean it up at work tomorrow and hopefully find the right heli-coil and get this thing going. Got a pan gasket ordered, should be here thursday or friday.

Does anyone know for sure the plug size?

12mm X 1.5mm?

DRAINPLUGMAGNETS.COM

A set of $15 digital calipers are are one of the most useful things you'll ever own.

 

[So-Crates]

You guys make sense... I guess my fear in using the heli-coil resides in "a properly installed" one - I just dont trust my mechanical skills enough!!!

So, dont mind me over here!

 

[JSharp]

You guys make sense... I guess my fear in using the heli-coil resides in "a properly installed" one - I just dont trust my mechanical skills enough!!!

So, dont mind me over here!

Seriously, they're no big deal to install. Drill and tap the hole straight and they work perfectly. Using blue loctite on the insert is good idea when you install it but that's really the only trick.

When you're done the threads will be better than new.

 

[kawtoy_77]

Seriously, they're no big deal to install. Drill and tap the hole straight and they work perfectly. Using blue loctite on the insert is good idea when you install it but that's really the only trick.

When you're done the threads will be better than new.

I use some stuff called "Indian Head" sealant...works excellent.

 

[JSharp]

I use some stuff called "Indian Head" sealant...works excellent.

Indian Head gasket shellac? If it's the brown stuff in a dauber bottle I've used that stuff for years on certain things. I still use a lot of the older sealants that have always worked for me.

Indian Head.
CopperCoat.
Gaskacinch or the tube equivalent HiTack.
Blue Loctite.

New mechanics want to use silicone on everything. Even in places where it works poorly if at all...

 

[KawiGrnNmyVeins]

Since you will have to tap it for a heli-coil....why not just go to an over-sized drain plug instead....you don't have to pull the pan...just grease the tap so all the metal sticks to it....I've done this with automotive parts alot....vasaline works great for holding the shavings to it....just use one the same pitch but the next size up...for example if it's 12mmX1.5mm go 13mmX1.5mm....just something to consider

 

[AP Guy]

Pan is already dropped, was very easy to do. Its just much easier to work with when its sitting on a work bench. I will actually probably run over to my parents place and mount it up on my dads Bridgeport. Should be perfectly square that way. Oversizing the hole will work but your still talking about aluminum threads with a steel plug. This way the threads will be steel on steel. Only thing the aluminum has to worry about is keeping the oil contained

I ordered a 12x1.5 kit today, should be here tomorrow. Looks like the weekend is going to be too busy to ride anyway but hopefully it will be ready to go by monday.