Drain plug hole stripped???

[Guest]

Well, I was feeling useful yesterday and decided to change the crankcase oil in my GS 450. Drained it, installed a new filter and o-ring and put the drain plug back hand tight. That is where the problem started. I put a small ratchet on the socket to put a bit more torque on it and it became loose again.....sinking feeling in my heart. I can get it snug, but not solidly tight before it goes loose again. Does this mean my threads are stripped out? Anybody ever had to heli-coil a drain plug hole? Tell me it's all a bad dream!!!

[80-81, GS 1100]

Several options and possibilities exist.

Use a new drain plug and see if its tight. I don't know if that
would work without being there. OR
Use a tap and dye kit to go to a larger sized.
My last choice would be Helicoil because in the long
run I would not want to depend on that for that
part.

Its been my experience that the plug will need
replacing before the hole but you may not be so lucky.

[bobthebiker88]

there exist several choices here. my first and preferred choice is a new oil pan with a non stripped drain hole, alternately, a timesert to repair the damaged threads.

[pete]

That sounds like the same sinking feeling I had when putting the gear shift drum arm in the crankcase and the Haynes torque listing was twice what it should be.

I'd be hesitant putting a helicoil in the pan too, and I'd be looking at the previous suggestion of tap and dye to go up a size, there's enough meat around there to do it.

[Greg B]

Heli-coil in my drain pan. No problem.

[olddaddy]

Thanks for all the replies and advice. I went ahead and bought another pan off of Ebay. I need to find a gasket now.......suggestions?

[Agemax]

Thanks for all the replies and advice. I went ahead and bought another pan off of Ebay. I need to find a gasket now.......suggestions?

ebay? or your local suzuki dealer

[SqDancerLynn1]

Another possibility is an over sized drain plug Motormite #65217 available at most auto part stores

[cowboyup3371]

Honestly, it was much cheaper for me to install a helicoil when I tried taking my bolt off the wrong way than it was to find a new oil pan. After the helicoil and a new washer I haven't had any leaks at all.

Good luck and yea, check the parts houses for a new gasket.

[Nessism]

Another possibility is an over sized drain plug Motormite #65217 available at most auto part stores

I've never used one myself but several members here have had good results with these.

[BassCliff]

Another possibility is an over sized drain plug Motormite #65217 available at most auto part stores

Hi,

I concur. This is a cheap, simple, long lasting repair. It's a no-brainer. Just get a new, slightly oversize drain plug and call it done.


Thank you for your indulgence,

BassCliff

[olddaddy]

I found a pan and gasket on ebay for under $20. Got an o-ring online and by next weekend I'll be riding again. Thanks for all the answers and advice, this forum really makes owning a nearly 30 year old Suzuki a lot more fun!

[Steve]

Another possibility is an over sized drain plug Motormite #65217 available at most auto part stores

I have done that on two bikes now.

Honestly, it was much cheaper for me to install a helicoil when I tried taking my bolt off the wrong way than it was to find a new oil pan.

It's even cheaper to get an oversized plug at Auto Zone.

I've never used one myself but several members here have had good results with these.

I am one of those members, I have done it twice now.

I concur. This is a cheap, simple, long lasting repair. It's a no-brainer. Just get a new, slightly oversize drain plug and call it done.

I found a pan and gasket on ebay for under $20. Got an o-ring online and by next weekend I'll be riding again. Thanks for all the answers and advice, this forum really makes owning a nearly 30 year old Suzuki a lot more fun!

Next time, don't be in so much of a hurry.

Glad that you are happy with your $20+ solution.

For about $2 for an oversize plug, you could have been riding the same evening you found it stripped.

.