How to fix your drain plug without splitting your cases

[Sandblaster]

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...

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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!

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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.

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[Sandblaster]

You may want to double check your drill bit size to be sure it is accurate.
This one is close enough:

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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.

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[Sandblaster]

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.

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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...

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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.

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[Sandblaster]

Pre test the length of your Helicoil.
They are a bit longer then required on the KX500..

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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..

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[Sandblaster]

Put your plug in and test fit...
Pour in some new oil, warm it up, and go flog it

[60something]

I know this is an old thread, but dude, your hand!!

That looks like stitches were in order...(I was looking for a "passing out" emoji

[Sandblaster]

Lol...
Yeah, stitches should have been done but... I was busy so, tape it up and call it good....

[60something]

I have to say, I've done that before too. That was sure a bad one though.

[Sandblaster]

Hows that 87 running?