Crush Washer Emergency

[apogeecustom]

Dern it! I've had this GS1000 for only a short while, and I've been super busy, but I managed to get in a lot of maintenance so far. Valves are done, carbs cleaned and synced. Did the front end (forks and such) last night because I'm doing a 5 hour ride tomorrow. I haven't done full oil service on it, but last night I dumped what was in it and added a fresh batch of oil. I'll get to full service later. When I was pulling the drain plug, it was on pretty good. There wasn't a copper washer, and it looked like there could be an aluminum crush washer (I cant remember what is spec) but it was pretty well squashed. So I'm packing up tonight for tomorrows ride and there's an oil spot I check the drain plug and sure enough its dripping slowly. So here's my little dilemma, the only place open right now would be a 24 hour Walmart. Are they going to have something I can use? I have a clean pan I can do a dump again. I have to leave pretty early so I can't wait for Autozone to open. What should I do?

[rapidray]

All of your spark plugs use the same size crush washer as your drain plug! Ray.

[apogeecustom]

All of your spark plugs use the same size crush washer as your drain plug! Ray.

Yes! I have a spare in my kit. Thanks Ray!

[apogeecustom]

So that was a good idea, but I had to dremel the threads off the spark plug to get the washer off without destroying it.

[herostar]

did it work for you?

[apogeecustom]

Not really. But I could have other issues with the pan plug hole. I haven't had time to deal with it. The plug was on very tight before so I don't know if the threads in the pan are damaged. I also haven't had time to get a good look at the pan surface where the washer rests so there could be some scoring thats letting oil through. I'm about to order a new plug and copper washer for safe measure and get back to the problem soon. I'll try to post what I find.

[BassCliff]

Hi,

Maybe it's time for an oversized, self-tapping drain plug?


Thank you for your indulgence,

BassCliff

[1948man]

So how in the heck can you get the crush washer off to replace it with a new one? I've got a few new crush washers but can't get the old one off my oil drain plug which is in good shape. Are you supposed to change the washer every oil change? The last couple of oil changes, I have just been leaving the old washer in place and am getting no drips. Thanks, Jim M

[1948man]

Yeah, I think I've heard of leaks developing when the 1st crush washer is not noticed and another is put on top of it. I'm thinking I will go one more change with the old washer and watch for drips. Maybe by my next change I will have learned enough additional profanities to get the washer off. Thanks for sharing you experiences.

[bwringer]

You could also just use a fiber washer.

If you use a clean drain pan and keep everything clean, you can just dump the oil back in.

However, a leaking drain plug means there's a strong possibility the threads are stripped as well.

[1948man]

I guess I can cuss better than I thought. I got it off without buggering the plug. Started with a small triangular shaped file and then tried the chisel method to finish up. I haven't had any problems with the drain plug or leaks. I just wanted to replace the crush washer and was afraid I might create a problem by trying to be diligent. All is good now.

[1_v8_merc]

You could try a light torch, to see if the washer would warp or get a little easier to take off.
(not sure if it would....but it's gotta be weaker than that big ol' bolt)

I don't recall having any problems with changing washers.

I've reused mine 3 or 4 times now.