Sump plug and stripped casing thread.

I'm in the middle of doing a service on the Gixxer and it appears the previous owner had stripped some of the thread off the casing when tightening up to the specified torque.

I can manage to get it "tightish" but any further and it spins.

What are my options in the local area? I've shopped around everywhere and i cant find a tap and die big enough for a larger sump bolt. Ideas?

In the mean time i've put on some sealant and leaving it to dry before filling with oil again.

Cheers guys.

Hi Jimbo.

If there's enough metal to do it, a re-thread and larger sump plug would be my first option. Secondly, you could try to find someone to Helicoil it. Third, get someone to ally weld the hole, re-drill and tap. Big risk of swarf in the sump with all the above though.

Be careful with your sealant and nip it up fix; if your plug comes out you'll have alot of hot oil pour straight out onto your rear tyre (not good!) and you're likely to damage or seize the motor (even worse!)

Sorry to be the bearer of bad news but give serious thought to alternative transport until it is properly fixed .

Rich

[Viney]

I know on the SV it isnt, but is the sump a seperate item on the gixer? If so, get a new sump, or what ^^^^ says

Originally Posted by Viney

I know on the SV it isnt, but is the sump a seperate item on the gixer? If so, get a new sump, or what ^^^^ says

Similar setup when it comes to a sump on the '97 Gixxer. I'll be phoning around on Monday about a Helicoil etc...

Am i better going round the smaller places or are there some big names that deal with them?

Any decent garage should have a helicoil kit!

Its just like a threaded spring they put in

Friend of mine stripped the thread on his Gixxer 750 when changing the oil. Turned the bolt the wrong way

Any way, he whipped the sump off and got a new thread inserted. Only thing he has to be careful of now is that the new thread has blocked the oil drainage channel, so more oil than normal will be left in the sump. (The channel is blocked off for about 3mm) But apart from that, good as new.

same happened to me yesterday mate,
taking the nut to drain the oil on the TLR and the previous owner over tightened it and bam i have threads in my hand,
dont know what size the hole is
but on the TLR its a 14mm hole so some clever guy on TLPLANET got one of these
http://www.cgenterprises.com/drain_p...ize_repair.htm
its item 1047
basically its a self tapper and you put red loctite on the threads(cause you never want it to come out)and to drain the oil you loosen the smaller bolt in the middle,
Seems like a good plan to me
I ordered one from the states and a fibre washer to seal her up good and well,
have a read of the thread here
http://tlplanet.com/forums/showthrea...threadid=17246
Cheers
Darren

Originally Posted by irl_dar

same happened to me yesterday mate,
taking the nut to drain the oil on the TLR and the previous owner over tightened it and bam i have threads in my hand,
dont know what size the hole is
but on the TLR its a 14mm hole so some clever guy on TLPLANET got one of these
http://www.cgenterprises.com/drain_p...ize_repair.htm
its item 1047
basically its a self tapper and you put red loctite on the threads(cause you never want it to come out)and to drain the oil you loosen the smaller bolt in the middle,
Seems like a good plan to me
I ordered one from the states and a fibre washer to seal her up good and well,
have a read of the thread here
http://tlplanet.com/forums/showthrea...threadid=17246
Cheers
Darren

You're a genius!!

Will order one and look around for a place to repair it as an alternative.

That sounds like a reasonable bodge :P Im sure it would work too, I would be concerned about thread swarf, just be careful fitting it. you may still have to clean the threads with a tap.

It looks like if you are going oversize you still need to drill and tap the hole

Originally Posted by irl_dar

basically its a self tapper and you put red loctite on the threads(cause you never want it to come out)and to drain the oil you loosen the smaller bolt in the middle,

Would i??

I've found it impossible to find a tap and die set for a 14mm plug as yet. The biggest i've found is a 12mm.