Differences
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techtalk:ref:engmech01d [2018/07/23 18:21] hippysmack [Source a temporary or alternate plug] |
techtalk:ref:engmech01d [2024/01/14 18:06] (current) hippysmack |
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| |62-65 XLCH| - | |707 Plug|704 Plug|45830-48 Plug| | |62-65 XLCH| - | |707 Plug|704 Plug|45830-48 Plug| | ||
| |67-71 XLCH|:::|:::|707 Plug|:::| | |67-71 XLCH|:::|:::|707 Plug|:::| | ||
| - | |||
| |61-62 , 704 crankcase plug - all sportsters (61 & 62 supplement) | |61-62 , 704 crankcase plug - all sportsters (61 & 62 supplement) | ||
| + | |{{:techtalk:ref:engmech:04_primary_drain_plug_by_luxblue.jpg?direct&300|}}| | ||
| + | | 04 Primary Drain Plug ((photo by LuxBlue of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/114944-pics-of-so-hot-bikes-hydraulic-chain-tensioner-install?t=1098213&highlight=oil+pump+spacer)) | | ||
| ==== Diagnosing where the leak is coming from ==== | ==== Diagnosing where the leak is coming from ==== | ||
| - | + | * Clean the area thoroughly. You want all the oil off the exterior surfaces. (( Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173827-crankcase-drain-plug/page3?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) | |
| - | * Clean the area thoroughly. You want all the oil off the exterior surfaces. (( Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) | + | * Get some white face powder and a powder puff kit like grandma had on her dressing table (white finger print powder and brush works great too). (( Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173827-crankcase-drain-plug/page3?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) |
| - | * Get some white face powder and a powder puff kit like grandma had on her dressing table (white finger print powder and brush works great too). (( Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) | + | * With exterior dry hit the inside with pb blaster, wd40, liquid wrench or kerosesne. Make sure you wet the suspected areas in the inside of case. (( Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173827-crankcase-drain-plug/page3?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) |
| - | * With exterior dry hit the inside with pb blaster, wd40, liquid wrench or kerosesne. Make sure you wet the suspected areas in the inside of case. (( Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) | + | * Now get the powder on the outside and you will see where the seep is coming from. (( Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173827-crankcase-drain-plug/page3?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) |
| - | * Now get the powder on the outside and you will see where the seep is coming from. (( Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1864035&highlight=Ironhead+Crankcase+Drain+Plug&page=3)) | + | |
| * If the plug is leaking, is not loose / will tighten up, you may have some warped threads that aren't allowing the flat surface on the back of the plug head to seal against the flat machined outer surface of the case. Over tightening from here will damage the threads even more. ((Hippysmack)) | * If the plug is leaking, is not loose / will tighten up, you may have some warped threads that aren't allowing the flat surface on the back of the plug head to seal against the flat machined outer surface of the case. Over tightening from here will damage the threads even more. ((Hippysmack)) | ||
| - | * Try pulling the plug, clean the threads and use some anti-seize on them. The anti-seize should seal up the threads as long as the crank case isn't building pressure and causing it to push some seepage out. ((wedge of the XLFORUM http://xlforum.net/forums/showthread.php?t=1958781&highlight=timing+hole+plug)) Teflon tape can also be used on the threads to prevent leakage. | + | * Try pulling the plug, clean the threads and use some anti-seize on them. The anti-seize should seal up the threads as long as the crank case isn't building pressure and causing it to push some seepage out. ((wedge of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/181856-plug-bolt-beneath-front-cylinder?t=1958781&highlight=timing+hole+plug)) Teflon tape can also be used on the threads to prevent leakage. |
| ====== Drain Plug Sealing and Temporary Fixes ====== | ====== Drain Plug Sealing and Temporary Fixes ====== | ||
| - | + | A tight mechanical seal on any of these plugs is what was intended originally from the MoCo as evident of how the plug was constructed. \\ However, when one of them leaks, it's not always cost efficient or convenient to have the threads repaired especially if your on the road with a bad leaking or blown out plug. \\ It may be just a drain plug, but results of a failed seal can be catastrophic. ((Moon Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer/page3?t=1164591&page=3)) | |
| - | A tight mechanical seal on any of these plugs is what was intended originally from the MoCo as evident of how the plug was constructed. \\ However, when one of them leaks, it's not always cost efficient or convenient to have the threads repaired especially if your on the road with a bad leaking or blown out plug. \\ It may be just a drain plug, but results of a failed seal can be catastrophic. ((Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591&page=3)) | + | |
| * Below is a collection of ideas for sealing up the plug until a solid mechanical seal can done. \\ If the health of the threads on the plug or in the case are questionable, only tighten the plug to just snug, plus a little. | * Below is a collection of ideas for sealing up the plug until a solid mechanical seal can done. \\ If the health of the threads on the plug or in the case are questionable, only tighten the plug to just snug, plus a little. | ||
| - | {{:techtalk:ref:engmech:drain_plug_fixes_by_sevenyears_of_famine.jpg?direct&400|}} ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=4)) | + | {{:techtalk:ref:engmech:drain_plug_fixes_by_sevenyears_of_famine.jpg?direct&400|}} ((photo by sevenyears of famine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page4?t=1461031&highlight=stripped+primary+drain&page=4)) |
| ==== Try a thread wrap just under the head of the plug ==== | ==== Try a thread wrap just under the head of the plug ==== | ||
| Use only enough to get a seal. Using too much could crack the case from the extra pre-load plus normal torque. | Use only enough to get a seal. Using too much could crack the case from the extra pre-load plus normal torque. | ||
| - | * Wrap some sewing string just below the head of the plug (wrapped in the direction of turn of the plug). ((ezmerf http://xlforum.net/forums/showthread.php?t=1676274&page=3)) | + | * Wrap some sewing string just below the head of the plug (wrapped in the direction of turn of the plug). ((ezmerf https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156603-leaking-drain-plug/page3?t=1676274&page=3)) |
| - | * Wrap some Teflon tape below the head. It's intended use is for tapered pipe threads, ((rivethog http://xlforum.net/forums/showthread.php?t=1676274&page=3)) and the OEM plugs use straight threads. | + | * Wrap some Teflon tape below the head. It's intended use is for tapered pipe threads, ((rivethog https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156603-leaking-drain-plug/page3?t=1676274&page=3)) and the OEM plugs use straight threads. |
| - | * Wrap a string off a mop around the plug below the head. ((Hopper http://xlforum.net/forums/showthread.php?t=1164591&page=2)) | + | * Wrap a string off a mop around the plug below the head. ((Hopper https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer/page2?t=1164591&page=2)) |
| ==== Try a thread sealant ==== | ==== Try a thread sealant ==== | ||
| - | |||
| Clean the plug and the hole of all oil and debris to get a good sealant hold. | Clean the plug and the hole of all oil and debris to get a good sealant hold. | ||
| * If the threads are not stripped (as in a bad sealing surface causing the leak), Loctite (blue) can be used as a sealant between the threads. \\ However, if the threads are stripped or are in bad shape, they may break off upon the next removal of the plug. | * If the threads are not stripped (as in a bad sealing surface causing the leak), Loctite (blue) can be used as a sealant between the threads. \\ However, if the threads are stripped or are in bad shape, they may break off upon the next removal of the plug. | ||
| - | * Loctite PST ((Monte03 http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=6)) thread sealant sticks cure rapidly to provide immediate low-pressure sealing. ((https://www.summitracing.com/parts/lct-37615)) \\ The controlled lubricity prevents galling, protects threaded areas from rust and corrosion, and provides easy disassembly. \\ Recommended for sealing metal tapered pipe threads and fittings in automotive applications. | + | * Loctite PST ((Monte03 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page6?t=1461031&highlight=stripped+primary+drain&page=6)) thread sealant sticks cure rapidly to provide immediate low-pressure sealing. ((https://www.summitracing.com/parts/lct-37615)) \\ The controlled lubricity prevents galling, protects threaded areas from rust and corrosion, and provides easy disassembly. \\ Recommended for sealing metal tapered pipe threads and fittings in automotive applications. |
| * Cover the plug with silicone, put the plug in the hole, turn it to get a wedged fit and let it dry. | * Cover the plug with silicone, put the plug in the hole, turn it to get a wedged fit and let it dry. | ||
| - | * Cover the plug with JB weld and let it set for about 2 days. ((Pan55 http://xlforum.net/forums/showthread.php?t=1810875&highlight=stripped+plug)) (you might want to use something else if you plan to remove the plug later). | + | * Cover the plug with JB weld and let it set for about 2 days. ((Pan55 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/168736-im-screwed-drain-plug?t=1810875&highlight=stripped+plug)) (you might want to use something else if you plan to remove the plug later). |
| - | * Cover the plug with RTV (black for oil). ((MRMIKEY32 http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=2)) | + | * Cover the plug with RTV (black for oil). ((MRMIKEY32 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page2?t=1461031&highlight=stripped+primary+drain&page=2)) |
| ==== Add a washer or O-ring to the plug to bridge the gap between poor sealing surfaces ==== | ==== Add a washer or O-ring to the plug to bridge the gap between poor sealing surfaces ==== | ||
| **Washers**: \\ | **Washers**: \\ | ||
| The I.D of the hole needs to correctly match the O.D. of the plug to keep the washer sealing surface on center with the hole. \\ The ID of this washer is too big and will not seal properly. \\ | The I.D of the hole needs to correctly match the O.D. of the plug to keep the washer sealing surface on center with the hole. \\ The ID of this washer is too big and will not seal properly. \\ | ||
| - | {{:techtalk:ref:engmech:1960_crankcase_oil_drain_plug_1_by_sevenyears_of_famine.jpg?direct&200|}} ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain)) | + | {{:techtalk:ref:engmech:1960_crankcase_oil_drain_plug_1_by_sevenyears_of_famine.jpg?direct&200|}} ((photo by sevenyears of famine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes?t=1461031&highlight=stripped+primary+drain)) |
| When using a soft washer like neoprene, rubber, fiber or nylon (plastic), first add a steel washer (if you have room) to spread the load on the soft one to keep it from distorting and possibly leaking. | When using a soft washer like neoprene, rubber, fiber or nylon (plastic), first add a steel washer (if you have room) to spread the load on the soft one to keep it from distorting and possibly leaking. | ||
| * A metal sealing washer (crush washer) made from copper or aluminum will compress when tightened to form a tighter, more durable seal than rubber washers (one time use). ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqjmm)) | * A metal sealing washer (crush washer) made from copper or aluminum will compress when tightened to form a tighter, more durable seal than rubber washers (one time use). ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqjmm)) | ||
| - | * **Copper washers** work well for sealing and the thin ones work much better than the thick ones. They meld in there better. ((Iron Mick http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain)) | + | * **Copper washers** work well for sealing and the thin ones work much better than the thick ones. They meld in there better. ((Iron Mick https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes?t=1461031&highlight=stripped+primary+drain)) |
| - | * They are used on banjo-bolts, brake systems, oil pipes etc. where heat, force, pressure and strong chemical fluids are present. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * They are used on banjo-bolts, brake systems, oil pipes etc. where heat, force, pressure and strong chemical fluids are present. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| - | * A copper washer can be tightened too hard and it will leak. After distortion from over-torque, it can get to the consistency of plastic and brake into small pieces. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * A copper washer can be tightened too hard and it will leak. After distortion from over-torque, it can get to the consistency of plastic and brake into small pieces. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| - | * If used with proper torque, a copper washer can be reused many times. It is possible to flip it around and it will seal again. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * If used with proper torque, a copper washer can be reused many times. It is possible to flip it around and it will seal again. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| - | * If a copper washer gets hard, you can heat it to a glow (with a propane torch for ten seconds) and let it cool down on it's own to the point you can handle it. Then it will be softer and re-usable. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * If a copper washer gets hard, you can heat it to a glow (with a propane torch for ten seconds) and let it cool down on it's own to the point you can handle it. Then it will be softer and re-usable. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| * **A metal-bonded neoprene sealing washer** is a one-piece metal washer with bonded rubber on the sealing surface. These washers are reusable. ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqyow)) | * **A metal-bonded neoprene sealing washer** is a one-piece metal washer with bonded rubber on the sealing surface. These washers are reusable. ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqyow)) | ||
| * **A high pressure metal-bonded sealing washer** has a rubber or plastic insert surrounded by a metal washer (one time use). ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqnfn)) | * **A high pressure metal-bonded sealing washer** has a rubber or plastic insert surrounded by a metal washer (one time use). ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqnfn)) | ||
| * The 316 stainless steel washers resist chemicals and salt water and may be mildly magnetic. They are bonded to a PVC insert. Pressure rated to 3,000 psi. | * The 316 stainless steel washers resist chemicals and salt water and may be mildly magnetic. They are bonded to a PVC insert. Pressure rated to 3,000 psi. | ||
| * The zinc-plated steel (**O-ring washers**) are corrosion resistant in wet environments and are bonded to a Buna-N rubber seal. Pressure rated to 3,000 psi. | * The zinc-plated steel (**O-ring washers**) are corrosion resistant in wet environments and are bonded to a Buna-N rubber seal. Pressure rated to 3,000 psi. | ||
| - | * The Dowty Bonded Seal (**Dowty Washer**) ((Nzhasher of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) is a synthetic rubber sealing member that is bonded with heat and pressure to a zinc plated steel washer. \\ The flexing action of the lip under pressure provides a positive and leak-proof seal. Depending upon size, pressures up to 20,000 p.s.i. (1380 bar). \\ The face to face sealing eliminates groove cutting or special machining and reduced bolting torque. \\ When bonded seals are used to seal tapped holes, the thread relief should never be greater than 0.01 in. (0.25 mm) above the nominal O.D. of the screw thread. ((http://www.potterassoc.com/pdf/bonded_seal_information_and_sizing_chart.pdf)) | + | * The Dowty Bonded Seal (**Dowty Washer**) ((Nzhasher of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) is a synthetic rubber sealing member that is bonded with heat and pressure to a zinc plated steel washer. \\ The flexing action of the lip under pressure provides a positive and leak-proof seal. Depending upon size, pressures up to 20,000 p.s.i. (1380 bar). \\ The face to face sealing eliminates groove cutting or special machining and reduced bolting torque. \\ When bonded seals are used to seal tapped holes, the thread relief should never be greater than 0.01 in. (0.25 mm) above the nominal O.D. of the screw thread. ((http://www.potterassoc.com/pdf/bonded_seal_information_and_sizing_chart.pdf)) |
| |{{:techtalk:ref:engmech:drain_plug_repair_8_by_xlchjoe.jpg?direct&300|}}| | |{{:techtalk:ref:engmech:drain_plug_repair_8_by_xlchjoe.jpg?direct&300|}}| | ||
| - | |Zinc-plated O-ring washers with allen head bolts. \\ Length cut to size. ((photo by xlchjoe of the XLFORUM http://xlforum.net/forums/showthread.php?t=1200190&page=59)) ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqnfn)) | | + | |Zinc-plated O-ring washers with allen head bolts. \\ Length cut to size. ((photo by xlchjoe of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/122189-what-did-you-do-for-your-sporty-today/page59?t=1200190&page=59)) ((https://www.mcmaster.com/#standard-sealing-washers/=1dlqnfn)) | |
| **O-rings**: \\ | **O-rings**: \\ | ||
| Use O-rings that are oil resistant for longevity of the seal. They should mesh into the sealing surface to stop a leak. \\ | Use O-rings that are oil resistant for longevity of the seal. They should mesh into the sealing surface to stop a leak. \\ | ||
| - | However, be careful upon installation. Lubricate the O-ring before installation or the sealing surface could rip it. ((Paul of the XLFORUM http://xlforum.net/forums/showthread.php?t=19984&page=2)) Also, not to over-torque the plug. This could result of distorting the rubber causing a leak or possibly squirting the O-ring out the sides of the plug. | + | However, be careful upon installation. Lubricate the O-ring before installation or the sealing surface could rip it. ((Paul of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/lubrication-and-lubricants/12030-what-is-the-stuff-the-factory-puts-on-the-drain-plugs/page2?t=19984&page=2)) Also, not to over-torque the plug. This could result of distorting the rubber causing a leak or possibly squirting the O-ring out the sides of the plug. |
| \\ | \\ | ||
| - | There is a difference in the seating surface for a O-ring and a washer. The O-ring seating area is normally more precise to keep from squeezing or ripping the O-ring. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) \\ | + | There is a difference in the seating surface for a O-ring and a washer. The O-ring seating area is normally more precise to keep from squeezing or ripping the O-ring. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) \\ |
| - | {{:techtalk:ref:engmech:helicoiled_plug_hole_2_by_sevenyears_of_famine.jpg?direct&300|}} ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=6)) The lip of a Helicoil can catch and rip an O-ring that has been over-torqued into it. | + | {{:techtalk:ref:engmech:helicoiled_plug_hole_2_by_sevenyears_of_famine.jpg?direct&300|}} ((photo by sevenyears of famine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page6?t=1461031&highlight=stripped+primary+drain&page=6)) The lip of a Helicoil can catch and rip an O-ring that has been over-torqued into it. |
| * Ideally, there should be groove in both facing surfaces to assure a good seal and to prevent squeezing of the O-ring. | * Ideally, there should be groove in both facing surfaces to assure a good seal and to prevent squeezing of the O-ring. | ||
| - | * Measure the length of threads left on the plug if you use an O-ring and a copper washer. \\ It's possible the plug would be too short to catch enough threads to tighten without stripping them. ((brucstoudt http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=5)) | + | * Measure the length of threads left on the plug if you use an O-ring and a copper washer. \\ It's possible the plug would be too short to catch enough threads to tighten without stripping them. ((brucstoudt https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page5?t=1461031&highlight=stripped+primary+drain&page=5)) |
| **A copper washer vs an O-ring**: \\ | **A copper washer vs an O-ring**: \\ | ||
| - | * A copper washer is made to seal with a larger force than an O-ring can handle. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * A copper washer is made to seal with a larger force than an O-ring can handle. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| - | * An example is the Evo primary oil drain plug fitted with a O-ring. ((chrissenator of the XLFORUM http://xlforum.net/forums/showthread.php?t=1164591)) | + | * An example is the Evo primary oil drain plug fitted with a O-ring. ((chrissenator of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/119773-rubber-o-ring-instead-of-copper-washer?t=1164591)) |
| * If we just consider that a copper ring is better and change from O-ring to copper then we generate a problem because the copper ring needs a \\ harder momentum to seal and we are walking on a thin line between a good seal and shreded threads from over-torque into the cast aluminum case. | * If we just consider that a copper ring is better and change from O-ring to copper then we generate a problem because the copper ring needs a \\ harder momentum to seal and we are walking on a thin line between a good seal and shreded threads from over-torque into the cast aluminum case. | ||
| * The plug screws in to soft aluminum and it takes very little force to tighten the O-ring and get a good seal. \\ It's all about using the right momentum. | * The plug screws in to soft aluminum and it takes very little force to tighten the O-ring and get a good seal. \\ It's all about using the right momentum. | ||
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| ==== Source a temporary or alternate plug ==== | ==== Source a temporary or alternate plug ==== | ||
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| * **A cork** in the hole has been used with various results. Be sure to have an extra or two on hand in the case that the first one blows out. | * **A cork** in the hole has been used with various results. Be sure to have an extra or two on hand in the case that the first one blows out. | ||
| - | * **A self expanding rubber plug** like the ones used for freeze plugs. They are removable and they expand by tightening the wingnut or bolt in the middle. ((milmat1 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1541235&highlight=colony+timing+hole+plug&page=3)). | + | * **A self expanding rubber plug** like the ones used for freeze plugs. They are removable and they expand by tightening the wingnut or bolt in the middle. ((milmat1 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/142250-more-ironhead-hate-hate-hate/page3?t=1541235&highlight=colony+timing+hole+plug&page=3)). |
| - | * **A bolt**. Cut a (same thread size) bolt down to the length of the (measured) hole. Making it a bit longer than the original plug, should allow you to catch the last bit of original threads where the shorter plug wouldn't. Measure up in the hole and don't make it too long to protrude inside the engine and catch on moving parts. ((Hopper http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=2)) | + | * **A bolt**. Cut a (same thread size) bolt down to the length of the (measured) hole. Making it a bit longer than the original plug, should allow you to catch the last bit of original threads where the shorter plug wouldn't. Measure up in the hole and don't make it too long to protrude inside the engine and catch on moving parts. ((Hopper https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/135180-oil-drain-plug-leaking-woes/page2?t=1461031&highlight=stripped+primary+drain&page=2)) |
| - | * **A piece of oil or gas line hose** that has an O.D. that will fit snug into the case hole. Find a bolt that has threads that are slightly larger than the inside of the hose. Screw the bolt into the hose and the threads of the bolt will expand the hose out against the case threads to seal the leak. ((CaptCaveman of the XLFORUM http://xlforum.net/forums/showthread.php?t=1541235&highlight=colony+timing+hole+plug&page=2)) | + | * **A piece of oil or gas line hose** that has an O.D. that will fit snug into the case hole. Find a bolt that has threads that are slightly larger than the inside of the hose. Screw the bolt into the hose and the threads of the bolt will expand the hose out against the case threads to seal the leak. ((CaptCaveman of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/142250-more-ironhead-hate-hate-hate/page2?t=1541235&highlight=colony+timing+hole+plug&page=2)) |
| - | * **A word of caution** when using automotive style __self-tapping oversized plugs__ when dealing with the crankcase drain. It may be okay for the transmission or primary compartment, but the crankcase drains on Ironheads are little different. ((mrmom9r of the XLFORUM http://xlforum.net/forums/showthread.php?t=1529653)) | + | * **A word of caution** when using automotive style __self-tapping oversized plugs__ when dealing with the crankcase drain. It may be okay for the transmission or primary compartment, but the crankcase drains on Ironheads are little different. ((mrmom9r of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/141121-oversize-plug-drain-plug?t=1529653)) |
| * The drain hole is very close to the edge of the case seam and more often than not the tapered self-tapping style will crack the case from the hole to the center seam of the cases. | * The drain hole is very close to the edge of the case seam and more often than not the tapered self-tapping style will crack the case from the hole to the center seam of the cases. | ||
| * Once that cracks you will have a leak that you can't stop short of a complete teardown. | * Once that cracks you will have a leak that you can't stop short of a complete teardown. | ||
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| |{{:techtalk:ref:engmech:self-tapping_oversized_repair_plug-piggyback_style_by_72_ironhead_xlh.jpg?direct&300|}}| | |{{:techtalk:ref:engmech:self-tapping_oversized_repair_plug-piggyback_style_by_72_ironhead_xlh.jpg?direct&300|}}| | ||
| - | | Self-Tapping Oversized Repair Plug (piggyback style) ((photo by 72 Ironhead XLH http://xlforum.net/forums/showthread.php?t=751303)) | | + | | Self-Tapping Oversized Repair Plug (piggyback style) ((photo by 72 Ironhead XLH https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/91972-primary-drain-plug?t=751303)) | |
| ====== Piggyback Drain Plug Mod for Stripped 1/2"x20 plug holes ====== | ====== Piggyback Drain Plug Mod for Stripped 1/2"x20 plug holes ====== | ||
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| * Drill the hole size for a slip fit for extra strength using dia. of the magnet you will be using (although this isn't a critical dimension). | * Drill the hole size for a slip fit for extra strength using dia. of the magnet you will be using (although this isn't a critical dimension). | ||
| - | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_1_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_2_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_3_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))| | + | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_1_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_2_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_3_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))| |
| * Apply epoxy in the hole, insert the magnet and let it dry. | * Apply epoxy in the hole, insert the magnet and let it dry. | ||
| * This can also be done in a vise or simply pushed in depending on the clearance you made while drilling the hole. | * This can also be done in a vise or simply pushed in depending on the clearance you made while drilling the hole. | ||
| - | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_4_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_5_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_6_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))| | + | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_4_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_5_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_6_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))| |
| * The shank length on this plug is 0.549". You can cut a slot thru any length of threads that protrude into the case past the hole. | * The shank length on this plug is 0.549". You can cut a slot thru any length of threads that protrude into the case past the hole. | ||
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| * A flat surface will allow you tighten the plug to the correct torque without extra warp-age to the case threads to get a good seal. | * A flat surface will allow you tighten the plug to the correct torque without extra warp-age to the case threads to get a good seal. | ||
| - | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_7_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_8_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_9_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2045306&highlight=primary+drain+plug))| | + | |{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_7_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_8_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))|{{:techtalk:ref:engmech:piggy_back_drain_plug_mod_9_by_zachary13.jpg?direct&300|}} ((photos by Zachary13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191707-my-primary-drain-plug-fix?t=2045306&highlight=primary+drain+plug))| |
| * Clean up any debris in the case and blow down the new threads with compressed air or WD-40 from the inside out to clean them of debris. | * Clean up any debris in the case and blow down the new threads with compressed air or WD-40 from the inside out to clean them of debris. | ||
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| * Install the copper washer and internal plug to 14-21 ft/lbs. | * Install the copper washer and internal plug to 14-21 ft/lbs. | ||
| * Check for leaks. | * Check for leaks. | ||
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