How to fix your drain plug without splitting your cases

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How to fix your drain plug without splitting your cases

Post by Sandblaster » Thu Nov 12, 2015 11:19 pm

So, your sick and tired of your drain plug leaking but you don't want to split your cases?
I would much rather do this with a bare case but it can be done without splitting the cases.
Here is the way we typically do it.
Number one... WASH YOUR BIKE!!!!!
Don't do it dirty as you will risk getting dirt in your engine...
Geese!!!!
Next lay your bike on it's side... No... Don't drain the oil first..
You will be using your old oil to help flush the engine...
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 101.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 101.JPG (160.64 KiB) Viewed 2673 times
Now remove the drain plug but be prepared for a little more oil to come out depending on how far the bike is laid over.
Did I mention you need one of these? Oops!
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 102.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 102.JPG (58.4 KiB) Viewed 2672 times
This is for a KX500 and most of Kawasaki's Dirt bikes use the same thread size which is a M10 x 1.5
You will also need some grease, and a 13/32" drill bit or .406" or about a 10MM, and some thread locker.
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 103.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 103.JPG (58 KiB) Viewed 2672 times
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Re: How to fix your drain plug without splitting your cases

Post by Sandblaster » Thu Nov 12, 2015 11:28 pm

You may want to double check your drill bit size to be sure it is accurate.
This one is close enough:
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 104.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 104.JPG (78.36 KiB) Viewed 2672 times
So now all the oil is drained out that is going to come out.
Wipe it off and get your drill ready.
Take the drill bit and apply a liberal amount of grease to the end of it.
This will help prevent or greatly reduce any aluminum chips from getting into your engine case.
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 106.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 106.JPG (41.23 KiB) Viewed 2672 times
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Re: How to fix your drain plug without splitting your cases

Post by Sandblaster » Thu Nov 12, 2015 11:40 pm

What I do is drill almost all the way through then I clean off my drill bit and reapply a liberal amount of grease to it.
Once you break through, try not to rev the drill motor up... low RPM's at this point is better then high rpm's.
Pull the drill out and prep your tap by greasing it just like you did with the drill.
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 107.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 107.JPG (40.31 KiB) Viewed 2672 times
Once again, stop when you are almost all the way through, clean the tap off, and reapply the grease.
Continue tapping until the tap goes at least a half inch into the motor to get full thread engagement.
When your done, back the tap out and clean any debris.
This is what your tap will look like...
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 108.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 108.JPG (51.76 KiB) Viewed 2672 times

Next, holding one finger over the drain hole, have a buddy lift the bike back straight up.
Have the oil pan under the bike and release your finger.
Your old oil will now come out helping to clear out any debris that may have been left inside.
I actually had some partial bottles of ATF that I dumped into the cases and let that drain through as well.
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 109.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 109.JPG (53.45 KiB) Viewed 2672 times
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Re: How to fix your drain plug without splitting your cases

Post by Sandblaster » Thu Nov 12, 2015 11:44 pm

Pre test the length of your Helicoil.
They are a bit longer then required on the KX500..
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 110.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 110.JPG (33.11 KiB) Viewed 2672 times
I like to pre cut mine to size but you can screw the Helicoil in and then gring it to size or use a pair of dikes to cut it.
I happen to have a diamond cutting tool for my porting tool so it works very nicely.. 8-)
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 111.JPG
OEM-CYCLE.COM KX500 DRAIN PLUG REPAIR 111.JPG (63.11 KiB) Viewed 2672 times
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Re: How to fix your drain plug without splitting your cases

Post by Sandblaster » Sun Aug 14, 2016 2:41 pm

Put your plug in and test fit...
Pour in some new oil, warm it up, and go flog it :lol:
If bikes are for kids I'll never grow up.

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