Stripped Drain Plug Woes - Second Update
Posted: Fri Oct 14, 2022 2:07 pm
Doing the 600 mile “break-in” service on my 1984 R80 G/S was going fine until I removed the drain plug for the shaft drive. I noted that the m12x1.5 bolt was stiff coming out and upon inspection realized that the coarse-threaded bolt elected to bring several threads along with it. I’ve had this bolt out once and reinstalled with a new aluminum crush washer to below spec torque but it seems the soft aluminum threads and the hungry coarse steel threads of the drain bolt were no longer getting along. Ugh.
So I’m faced with a few decisions.
1. Attempt to drill it out on the bike, flush the shaft with kerosene to hopefully remove all the bits of aluminum and then install a helicoil. $80 - Fast
2. Buy the tools to remove the pinion nut and partially tear the FD down to allow the work to be done on the bench and eliminate the potential for contamination from any leftover bits of metal. Finding a way to secure the FD to employ a drill press will be tricky. $200-$300 A week or 2.
3. Send the FD out to Ande @ Barrington to rebuild, replace the large ring gear bearing, and the pinion double row ball bearing, fresh seals and of course drill, tap and timesert the drain threads. $500-$1500? 2-3 weeks at best.
If I elect 2 or 3 I’m faced with the bike being non-op for some of the last beautiful riding weeks of autumn which is a real drag after spending nearly a year restoring this motorcycle to service but so it goes. I guess I can slum it on my R69S or another of my older bikes in the meantime.
Please give your honest input. Of course cost/time is a factor but I’m also the sort of mechanic/rider who prefers to do it right and do it once. The FD isn’t currently leaking so the current seals seem ok but I do have a very minor tick of play which would likely be resolved with the replacement of those bearings.
Thanks!
So I’m faced with a few decisions.
1. Attempt to drill it out on the bike, flush the shaft with kerosene to hopefully remove all the bits of aluminum and then install a helicoil. $80 - Fast
2. Buy the tools to remove the pinion nut and partially tear the FD down to allow the work to be done on the bench and eliminate the potential for contamination from any leftover bits of metal. Finding a way to secure the FD to employ a drill press will be tricky. $200-$300 A week or 2.
3. Send the FD out to Ande @ Barrington to rebuild, replace the large ring gear bearing, and the pinion double row ball bearing, fresh seals and of course drill, tap and timesert the drain threads. $500-$1500? 2-3 weeks at best.
If I elect 2 or 3 I’m faced with the bike being non-op for some of the last beautiful riding weeks of autumn which is a real drag after spending nearly a year restoring this motorcycle to service but so it goes. I guess I can slum it on my R69S or another of my older bikes in the meantime.
Please give your honest input. Of course cost/time is a factor but I’m also the sort of mechanic/rider who prefers to do it right and do it once. The FD isn’t currently leaking so the current seals seem ok but I do have a very minor tick of play which would likely be resolved with the replacement of those bearings.
Thanks!