Best Stripped Oil Pan Screw Solution, maybe?

[79 sh850]

Why not have a helicoil professionally installed? That way you can keep your stock drainplug.

If I went this route, I would probably seat it with a fresh copper washer at every oil change to get a good seal without having to use a lot of torque.

 

[peterpressure]

Started new thread for my question: Oversized Drain Plug to long

 

[jonp84]

Solution!

Solution!

I found a solution to the problem. At the moment I am completely broke (as I munch on a peanut butter sandwich on Safeway bread) because I bought the bike while living month-to-month on a student's income. So I didn't have the funds to fix the oil pan right (either weld something then rethread, or better yet just get a new one). So here is an outline of what I did that worked as a temporary fix, in case anybody else ever is in this situation.

I fabricated a tool out of 1/8" plate steel that I cut to about a 0.3" wide strip. The tool fit through the oil pan drain hole and had a hook on the top that could grab the tab that protrudes into the oil pan. I hooked the tab, then used the tool to bend it in slightly (I know there was a risk of breaking the tab, I was careful). With this done, the oil pan plug threaded fine, but had a very slight leak (several drips overnight). So I redrained the oil, cleaned the contact surfaces and applied an aerosol gasket to the drain screw, then screwed it in and tightened it to spec. I let the gasket set up, refilled the bike with oil, and it doesn't leak at all.

I wouldn't recommend this method if you have other options, but it works for a temporary fix. Next time I change the oil I will just replace the oil pan. Thanks for your help everybody!