Differences

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--- techtalk:ref:engmech01e [2018/07/06 02:21]
hippysmack [Timing Inspection Plug / Drain Plug Sealing and Temporary Fixes]
+++ techtalk:ref:engmech01e [2018/07/07 18:50]
hippysmack [Installing a Helicoil on a Drain Plug with the Engine in the Frame]
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== REF: Engine Mechanicals - Sub-01E ======
-====== Timing Inspection Plug / Drain Plug Sealing and Temporary Fixes ======
+====== Installing a Helicoil on a Drain Plug with the Engine in the Frame ======
-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 badly leaking or blown out plug.
+  * Drain the engine / primary oils and the gas tank.
+  * Remove the battery.
+  * Lay the bike over on it's side on a sheet or blanket for protection.
+  * Slip some plywood under the sheet if your on asphalt or concrete to keep from scratching things.
-  * Below is a collection of ideas for sealing up the plug until a solid mechanical seal can done.
+{{:techtalk:ref:engmech:primary_drain_plug_repair_1_by_freewheeler.jpg?direct&400|}} ((photo by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))  {{:techtalk:ref:engmech:drain_plug_repair_1_by_xlchjoe.jpg?direct&400|}} ((photo by xlchjoe of the XLFORUM http://xlforum.net/forums/showthread.php?t=1200190&page=58))
-  * Try a thread wrap just under the head of the plug and re-install it. To tighten, just snug it up, plus a little.
+  * Using a drill with a handle will help keep the hole square. The hole needs to be good and straight for the new plug to seal.
-    * Wrap some sewing string just below the head of the plug. ((ezmerf http://xlforum.net/forums/showthread.php?t=1676274&page=3))
+  * You can also buy a bushing with a good flush end and drill thru it while keeping it tight against the case to help keep the hole straight.
-    * 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. \\ Use only enough to get a seal. Using too much could crack the case from the extra pre-load plus normal torque.
-  * Try a thread sealant.
+|  Helicoiled threads have to be tapped straight with the sealing surface to allow a 360º \\ seal underneath the plug head or the plug will leak. ((photo by xlchjoe of the XLFORUM http://xlforum.net/forums/showthread.php?t=1200190&page=58)) ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1461031&highlight=stripped+primary+drain&page=6))  ||
+|{{:techtalk:ref:engmech:drain_plug_repair_2_by_xlchjoe.jpg?direct&300|}}|{{:techtalk:ref:engmech:helicoiled_plug_hole_1_by_sevenyears_of_famine.jpg?direct&300|}}|
+  * Before drilling, the hole was packed with grease and a small piece of stainless was put on the other side to keep from drilling \\ anything and (hopefully) stopping some of the chips from falling further into the engine. ((photos by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))
+{{:techtalk:ref:engmech:primary_drain_plug_repair_3_by_freewheeler.jpg?direct&300|}}  {{:techtalk:ref:engmech:primary_drain_plug_repair_4_by_freewheeler.jpg?direct&300|}}
+  * This Helicoil kit (1/2" UNF) was used. ((photos by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))
+{{:techtalk:ref:tools:helicoil_kit_by_freewheeler.jpg?direct&300|}}  {{:techtalk:ref:engmech:primary_drain_plug_repair_5_by_freewheeler.jpg?direct&300|}}
+  * Tapped straight, cleaned up with the Helicoil installed. ((photos by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))
+  * With a pair of extremely sharp cutters, a couple of turns were cut off the insert before winding it into the case to shorten it.((photos by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))
+{{:techtalk:ref:tools:tap_wrench_by_freewheeler.jpg?direct&400|}}  {{:techtalk:ref:engmech:primary_drain_plug_repair_7_by_freewheeler.jpg?direct&400|}}
+  * The new drain plug was fabricated using an ordinary bolt (1/2" UNF) and a spare magnet.
+  * The end of the bolt was drilled out and the magnet was glued in with some impact adhesive.
+  * Finished it up with a copper washer on the bolt (not pictured). ((photos by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug))
+{{:techtalk:ref:engmech:primary_drain_plug_repair_8_by_freewheeler..jpg?direct&300|}}  {{:techtalk:ref:engmech:primary_drain_plug_repair_9_by_freewheeler.jpg?direct&300|}}  {{:techtalk:ref:engmech:primary_drain_plug_repair_10_by_freewheeler..jpg?direct&300|}}

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