leaking oil from sump plug

shaba2000 · Nitrous Nuisance Joined: 16 Apr 2006 Karma :

on my kawasaksi gpz500s 1996 i relaised that there is oil leaking from the sump plug at bottom og engine.

I tries to tighten the plug but it keeps turning so i emptyed all the oil out and had a look at teh thread on the plug and it seems fine however it seems the tread in the engine has worn towards the end which is why the sump plug is not tightening in correctly.

is there any way i can get the hold which the sump plug goes into re-threaded? or am i doomed?

Bezzer · World Chat Champion Joined: 14 Apr 2005 Karma :

You'll have to take the sump off and take it to a bike or engineering place to have it helicoiled or similar. Waste of time pissing about with bodges as it will eventually let go big time.
Won't be too expensive, and don't forget to buy a new sump gasket and sump bolt sealing washer for when you put it back together.
It's a common problem caused mainly by people not bothering to replace the sump washer when they change oil meaning you use more and more torque to seal it until it fails instead of paying less than a quid for a new crush washer each time.
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Nath · World Chat Champion Joined: 28 Jul 2004 Karma :

The thread in the sump is stripped. You might be able to repair it by running a tap down the thread, however it may well be too far gone for that.

If so, options are to drill and helicoil it, or drill it out and tap it to the next size up. Any decent workshop should be able to do either of these, and if you remove the sump yourself it shouldn't be too expensive.

A temporary bodge would be to use ptfe tape on the full length of the sump bolt then tighten it in as far as it will go. Hopefully it would not be pissing out oil everywhere.
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stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

You might be able to 'tidy up' the threads by running a greased tap up them. Failing that it is either helicoil or drill and tap to the next size up.
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shaba2000 · Nitrous Nuisance Joined: 16 Apr 2006 Karma :

ok thanks guys.. Will try get a appointment booked in the garage this week as it started out dripping but now is leaking more and more.

shaba2000 · Nitrous Nuisance Joined: 16 Apr 2006 Karma :

i was just thinking. would it be possible for me to go to a scrap yard and get the bottom half of the crank case and just swap them over?>

does anyone know if the bottom half of crank case come off my bike?

or would i be able to get the oil pan and just change that over?also how difficult is it?

thanks

veeeffarr · Super Spammer Joined: 22 Jul 2004 Karma :

I didn't know you were supposed to replace the crush washer at every oilchange :O

T

tonytango · Two Stroke Sniffer Joined: 22 May 2006 Karma :

Yep Toby, I know the dealers and the manufacturers winge on about it ...but this is one thing you must do otherwise ,as you know by now, it will cause problems in the future.... a simple rule is, if you have got a service and repair manual and it states that you must replace washers,bolts,screws etc.. then it is always best that you follow the dealers and the books advice....always remember it is always best to spend a pound on a replacement bolt,screw,washer then it is spending a ton replacing the damage afterwards...

just my 2 bits

tony Cool

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ZRX61 · Victor Meldrew Joined: 05 Nov 2003 Karma :

veeeffarr · Super Spammer Joined: 22 Jul 2004 Karma :

Bah, nearest decent bike shop to me is abour 40 miles away and I work WELL beyond its opening times, I just check how servicable they look usually.

T

0ddball · World Chat Champion Joined: 15 Jul 2005 Karma :

Bike shop? It's a plain old copper washer. Any motor factors will have trays full of them.

shaba2000 · Nitrous Nuisance Joined: 16 Apr 2006 Karma :

okay guys erm the topic in hand please Razz

i just got this bike its my first bike and trust me i know to change the washers but the guy before me never did which probably cause this..

my point is...can the oil drain pan be replaced or taken off a kawaskai gpz 500s 96 model?

thanks

0ddball · World Chat Champion Joined: 15 Jul 2005 Karma :

Yes, piece of cake. Take the exhaust off. Drain the oil and remove the filter. Undo the 10 sump bolts and lower the sump.

You'll need to order a new gasket.

shaba2000 · Nitrous Nuisance Joined: 16 Apr 2006 Karma :

okay thats great thanks