argh ffs

[woll]

My bandit had a slight leak on the sump plug and the oil looks fairly fresh (only had it a week) so i thought ah it's not been tightened up quite enough or the washers foobar (so i ordered a new sump plug with washer), put spanner on went to tighten it and it felt like it had was coming undone. I new exactly what had happened, i was hoping that it hadn't but it has, i slowly undid the sump plug and low and behold the threads started falling onto my hand .
https://i649.photobucket.com/albums/uu211/whalley1992/Bikes/DSC00398.jpg
That's what i was met with. Some gorilla has overtightened the sump plug and stripped the threads out of the engine. the new sump plug will tighten up to a certain point then it just goes loose.

I did the same thing on my 50cc bike a few years back and plumbers ptfe tape managed to seal it. So i thought it was worth a go on the bandit. I've put some on the nut and tightened it up and it does go tight at the top. Will i be ok to torque it to the manufacturers spec? Or will it just do the same again?
Will it do as a fix or should i book it into a garage to have it helicoiled or sumat? And what kind of price should i expect to pay?

Ta lads
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[steveh]

it will leak again, simple as.

Either tap it out and find a bigger plug, or take the sump plate? off and get it helicoiled, not expencive really, or get a kit and do it yourself.

If you bodge it and it fails, its likley to go all over your rear wheel and spit you off or kill you, is it worth the risk?


do the job properly then you dont have to worry about it anymore.


steve.
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Current : 06 Zx10r, 07 Wr450f SM, 74 850 norton commando, 63 bsa b40, 1962 Triton 650, 67 Triumph Tr6r, 1955 Triton 750, 1978 TY250E.

[Vincent]

If the Bandit has a seperate one, it might be easier & cheaper to try and find a used sump plate.

[woll]

Would it be as simple as just getting the right size tap and tapping it out? or would i have to take the sump off and drill it? or some other procedure?
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Vincent]

[Vincent]

One of these might work:-

https://www.timesert.com/

[woll]

[Vincent]

[quote="woll"]

[woll]

Depends on what you mean by a plate? It has a removable sump, so i could just unbolt it then either do it myself or get somebody else to helicoil it.
Would it be possible to use some instant gasket on the sump if i take it off? Monies going to be tight for a week or two and i need the bike for work and i've got instant gasket in the shed.
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Vincent]

If the old gasket comes off in one piece, just use a bit of blue Hylomar or similar.

[woll]

Well looks like im taking my sump off tomorrow i have a feeling the downpipes will have to come off too i hope whoever put stainless pipes on put some copperslip on the studs
Ah well gives me chance to do the fork seals i suppose.
Don't suppose anybody knows if i can change them while the forks are still on the bike? I've only got my MX bike lift and it wont fit under the bike to take them off.
Ooo and i can polish the downpipes if i get them off lol
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Pete.]

You don't need a blind hole to fit a helicoil. I fitted one in my 'busa sump. When you use the insertion tool to fit the coil it works by twisting the spring which reduces the diameter allowing it to screw into the thread you cut. WHen you stop turning the spring expands and grips into place. You then snap the tang off.

You don't need to strip the sump off if you can get on it with the helicoil tool either. There will be a minimal amount of swarf but a quick oil change will shift that and any not carried out by that will be left harmlessly in the bottom of the sump.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[woll]

Oooooo sounds good to me pete local engineering place is 3 miles away and im 100% that they could helicoil it, i may just bodge it to seal then ride it there and get them to helicoil it. Unless i find somebody with a helicoil kit, cos i dont fancy paying £50 for something im only going to use once lol
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[woll]

Any tips on doing my fork seals? never done any before, i have got a haynes but i find them confusing at times lol. I presume i will have to take the forks apart or will i be able to do them while they're on the bike? And what weight and how oil do the bandit 600 forks need?
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[GSF Jamie 600]

[Vincent]

Obviously, you can't replace the seals whilst the forks are on the bike but you can replace them without taking the forks apart. However, IMO, it's ususaly best to strip the forks so that you can clean off all the old oil and check the bushes, (Worn bushes can be one reason the seals gave up in the first place). The hard part is getting the stantion and leg apart - it can take a lot of force.

[woll]

Hellllppppp lol

Took the left hand fork off the bike today 'cos all the bits have come. Thought i was doing well, got the wheel off, turned the dampner bolt in the bottom of the stanction, undid the top bolt, took it off the bike. Then went to completely undo the damper bolt but it just turns So i put forks back together and onto the bike tried again but it wouldn't undo. I pulled it in all different ways put forks together put weight on them and tried to undo the damper bolt but i can't anybody got any ideas on how to do it? I can't afford to pay somebody to do it.
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Vincent]

[woll]

Yeah i just read on the internet bout using a broom handle, so i fettled the end of the handle to a similar shape of the tool suzuki use and the bloody broom handle snapped when i turned the allen key leaving me with a chunk of broom handle inside the stantion that i can't grip.

So much for what i read about it only being a 2 hour job for the seal replacment lol
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Vincent]

[woll]

Going to have another brew brake lol getting wound up with it now
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[DrDonnyBrago]

Never had much success with the broom handle either tbh, it needs a short sharp whack to undo the bottom damper bolt.

A mechanics airgun is perfect and will usually do it in no time either for free or for a few quid of beer money.

[woll]

no mechanics like that round here, all want stupid amounts for little work (the ones i know anyway). I know one of my bosses has an impact gun for his compressor but its fooking huge iirc its 3/4 drive so no chance of using that for the job
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Blau Zedong]

Get the right helicoil kit and you can do it in situ without removing the sump pan and without going up a size on the thread. I'll see if I can find the size tonight as I have done this myself on a GSXR750 (Same bottom end) and should still have the helicoil kit somewhere. Once I'd done the helicoil I poured a couple of litres of cheap shit oil into the engine to flush any swarf away, then refitted the sump plug with a new washer.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

[woll]

Just to check, if i do get hold of an impact gun. Do i still need the tool to hold the insides?

And so that im not fucking around for days, do i need to get the damper out to remove the stanction? or do i just need to give the stanction a good pull?

And is it right that i might be able to use a self tapping screw to pull the oil seal out?
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt