This is an old revision of the document!
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.
- 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)
2)
photo by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1852458&highlight=stripped+plug
3)
photo by xlchjoe of the XLFORUM http://xlforum.net/forums/showthread.php?t=1200190&page=58