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REF: Engine Mechanicals - Sub-01E

Installing a Helicoil on a Drain Plug with the Engine in the Frame

Article by Freewheeler of the XLFORUM 1)

  • 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.

2) 3)

  • 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.
  • 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. 4)

  • This Helicoil kit (1/2“ UNF) was used. 5)

  • Tapped straight, cleaned up with the Helicoil installed. 6)
  • 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.7)

  • 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). 8)


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