ADVrider

Go Back   ADVrider > Bikes > GSpot > GS Boxers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 03-04-2012, 09:27 AM   #1
GSWayne OP
Old Guy nOOb
 
GSWayne's Avatar
 
Joined: Mar 2005
Location: Santa Barbara
Oddometer: 2,944
FD Drain Plug Buggered Threads Fix

In case some other fumble fingered home mechanic cross threads the drain plug on an 05 R1200GS Final Drive here is what I did to fix it. I thought about trying to clean up the threads with a tap but it is an unusual thread, 12 mm x 1 mm pitch so I didn't have a tap and I doubt if any place in Santa Barbara had one (standard 12 mm pitches are 1.5 and 1.75 mm). I was also concerned that tap would start wrong and cut new wrong threads. So I decided just to remove the first few damaged threads, because there were plenty of good threads left.


So I made a brass bushing to protect the sealing surface and center the cutter.


That just fit a 1/2" counter sink


And using a hand drill, carefully cut away the bad threads and left a tapered guide into the good threads. With thick cutting oil on the countersink, frequent cleaning of the countersink and hole, and blowing air into the fill port of the FD I don't think I got any aluminum chips in the FD. Now the plug went in fine. Typical case of one of those simple one hour jobs turning into an exciting afternoon of improvised repairs.

All you brain surgeons in the audience you will recognize the hand drill as standard issue in an expendable brain surgery kit (no I am not a brain surgeon and don't even play one on TV).
__________________
It isn't the conditions its the decisions

Don't bring a motorcycle to a car fight
GSWayne is offline   Reply With Quote
Old 04-25-2013, 05:28 PM   #2
John Smallberries
Beastly Adventurer
 
John Smallberries's Avatar
 
Joined: Aug 2009
Location: Northville, Michigan
Oddometer: 1,247
Crap!!! I just did this

I"m glad I found this old thread - as I just did this on my '05 1200GS - turning an 30-minute final drive oil change into an "oh shit - now what" moment. I'm stopping at the dealership tomorrow to see if they have any tap to help me out.
__________________
'05 BMW 1200GS
'09 Honda CRF230
'10 Yamaha TW200
John Smallberries is offline   Reply With Quote
Old 04-25-2013, 05:45 PM   #3
hammick
Beastly Adventurer
 
hammick's Avatar
 
Joined: Dec 2007
Location: Kansas City, Missouri
Oddometer: 1,429
Don't feel bad guys. I stripped out the fill hole on the final drive on an '07 GSA two days before I was to leave on a 3k mile trip. The plug would just spin and I couldn't get it out either. I packed around the plug with JB Weld and it held until I traded it in at which point the dealer put in a helicoil and fixed it proper. The metal on the final drives is soft. I couldn't find a torque spec so I assumed it was the same as the tranny fill. Wrong! Tranny is hard steel. Final drive is not. I don't use a torque wrench on the final drive any more.
__________________
2015 R1200 GSA
2014 S1000R
2013 KTM 500 XC-W
hammick is offline   Reply With Quote
Old 04-25-2013, 06:35 PM   #4
JimVonBaden
"Cool" Aid!
 
JimVonBaden's Avatar
 
Joined: Feb 2005
Location: Alexandria, VA
Oddometer: 49,385
Quote:
Originally Posted by hammick View Post
Don't feel bad guys. I stripped out the fill hole on the final drive on an '07 GSA two days before I was to leave on a 3k mile trip. The plug would just spin and I couldn't get it out either. I packed around the plug with JB Weld and it held until I traded it in at which point the dealer put in a helicoil and fixed it proper. The metal on the final drives is soft. I couldn't find a torque spec so I assumed it was the same as the tranny fill. Wrong! Tranny is hard steel. Final drive is not. I don't use a torque wrench on the final drive any more.
Torque value for the plug is "good-n-snug" and no more!

Jim
JimVonBaden is offline   Reply With Quote
Old 04-25-2013, 07:49 PM   #5
rdwalker
Beastly Adventurer
 
Joined: Jan 2005
Location: The Badlands (of NJ)
Oddometer: 2,529
Quote:
Originally Posted by JimVonBaden View Post
Torque value for the plug is "good-n-snug" and no more! ... Jim
WRONG!

Tighten until it strips, then back off a quarter turn.

(Could not resist... )
rdwalker is offline   Reply With Quote
Old 04-25-2013, 08:08 PM   #6
JimVonBaden
"Cool" Aid!
 
JimVonBaden's Avatar
 
Joined: Feb 2005
Location: Alexandria, VA
Oddometer: 49,385
Quote:
Originally Posted by rdwalker View Post
WRONG!

Tighten until it strips, then back off a quarter turn.

(Could not resist... )


Jim
JimVonBaden is offline   Reply With Quote
Old 04-26-2013, 12:54 AM   #7
Spyker
Gnarly Adventurer
 
Joined: Dec 2003
Location: Planet Earth
Oddometer: 186
Quote:
Originally Posted by rdwalker View Post
WRONG!

Tighten until it strips, then back off a quarter turn.

(Could not resist... )
That is known in the industry as Suzuki tight.
__________________
Quote:
Originally Posted by scottie boy
If you calculated the money spent versus time actually used, vaginas cost more per hour than the space shuttle.
Spyker is offline   Reply With Quote
Old 04-26-2013, 02:40 AM   #8
John Smallberries
Beastly Adventurer
 
John Smallberries's Avatar
 
Joined: Aug 2009
Location: Northville, Michigan
Oddometer: 1,247
My plan - bad as it is

I also have a 1900 mile trip coming up next weekend and an off-road day with a bunch of guys tomorrow. I want my GS back TODAY (gotta try out my new Hiedenau rear tire).

So here is my plan - bad as it is:
A) Visit the dealer to ask their advice and get a price for a proper fix, should my other plans fail. Take whatever advice they give me (I'm a bit afraid of my ability to execute the good fix that started this thread!)
B) Buy a new drain plug and o-ring
C) Try tonight to clean out the old thread (only the top aluminum thread is bad, the rest look fine) with a dental pick (or other technique recommended)
D) If C fails, I'll grind all the threads off my old plug, slip it in to get the O-ring to seal, then apply some Sugru to hold it in place. This should "protect the crime scene" for a proper repair of the aluminum threads at a later date.

I feel like a complete dumb-ass today!
__________________
'05 BMW 1200GS
'09 Honda CRF230
'10 Yamaha TW200
John Smallberries is offline   Reply With Quote
Old 04-26-2013, 02:52 AM   #9
RFVC600R
SAND EATER!
 
RFVC600R's Avatar
 
Joined: Dec 2011
Location: SAND LAND
Oddometer: 2,256
Quote:
Originally Posted by John Smallberries View Post
I feel like a complete dumb-ass today!
I met a guy with a (83'?) XT550 yesterday. I thought my bike was in bad condition, but that thing was uglier than mine and the frigging thing pissed oil, like literally He said he bought it and the PO was doing the clutch and stripped all but two of the crankcase bolts and two of the three oil filter bolts. Got it for cheap needless to say, but I'm surprised one could ride something like that. let alone strip almost all the bolts. I need to carry around a camera, this dude matched his bike.

Don't feel bad!
__________________
'83 Honda XL600R 618cc 11:1 Wiseco, XR's Only Exhaust, big tube header, 6 Sigma stage 3 carb mods

Quote:
Originally Posted by Carter Pewterschmidt View Post
He's the XL600 Jesus, his bike dies for our sins.
RFVC600R is offline   Reply With Quote
Old 04-26-2013, 03:00 AM   #10
John Smallberries
Beastly Adventurer
 
John Smallberries's Avatar
 
Joined: Aug 2009
Location: Northville, Michigan
Oddometer: 1,247
JVB Tech Day

JVB;
This should give you a good "what not to do" lesson for your Tech Day!

That looks like a good time, BTW.
__________________
'05 BMW 1200GS
'09 Honda CRF230
'10 Yamaha TW200
John Smallberries is offline   Reply With Quote
Old 04-26-2013, 04:17 AM   #11
JimVonBaden
"Cool" Aid!
 
JimVonBaden's Avatar
 
Joined: Feb 2005
Location: Alexandria, VA
Oddometer: 49,385
Quote:
Originally Posted by John Smallberries View Post
JVB;
This should give you a good "what not to do" lesson for your Tech Day!

That looks like a good time, BTW.


Should be fun.

On your drain plug, is the O-ring showing, or still inside the FD?

Jim
JimVonBaden is offline   Reply With Quote
Old 04-26-2013, 05:12 AM   #12
John Smallberries
Beastly Adventurer
 
John Smallberries's Avatar
 
Joined: Aug 2009
Location: Northville, Michigan
Oddometer: 1,247
Drain plug

Quote:
Originally Posted by JimVonBaden View Post


Should be fun.

On your drain plug, is the O-ring showing, or still inside the FD?

Jim

O-ring is in good condition and still on the drain plug. The hole in the FD looks clean as well, I just can't find the start to the first thread. All the threads beyond the first look fine. It isn't an over-torque issue - I think I just cross threaded the plug as I was trying to re-install. The hole is at an odd angle - but I didn't think I could damage the threads with just finger-torque. These 12x1mm are very fine and fragile. To make things worse, our diabolical pals in Germany didn't put a dog-point on the plug to help get it started.
__________________
'05 BMW 1200GS
'09 Honda CRF230
'10 Yamaha TW200
John Smallberries is offline   Reply With Quote
Old 04-26-2013, 05:27 AM   #13
JimVonBaden
"Cool" Aid!
 
JimVonBaden's Avatar
 
Joined: Feb 2005
Location: Alexandria, VA
Oddometer: 49,385
Quote:
Originally Posted by John Smallberries View Post

O-ring is in good condition and still on the drain plug. The hole in the FD looks clean as well, I just can't find the start to the first thread. All the threads beyond the first look fine. It isn't an over-torque issue - I think I just cross threaded the plug as I was trying to re-install. The hole is at an odd angle - but I didn't think I could damage the threads with just finger-torque. These 12x1mm are very fine and fragile. To make things worse, our diabolical pals in Germany didn't put a dog-point on the plug to help get it started.
Gotcha. Use a small 90 pick and chase the threads from the inside out. If the last thread is loose, break it off so you have a clean start.

Jim
JimVonBaden is offline   Reply With Quote
Old 04-26-2013, 04:12 PM   #14
rdwalker
Beastly Adventurer
 
Joined: Jan 2005
Location: The Badlands (of NJ)
Oddometer: 2,529
Quote:
Originally Posted by Dracus124 View Post
... the frigging thing pissed oil, like literally ...
There is a serious side to this - though it is open to all our jokes and sneers in previous posts.

The problem is that dripping oil may coat the rear tire. Then it's "To the Moon, Alice!".

Call me a coward, but I, for one, would never ride with an active leak.
rdwalker is offline   Reply With Quote
Old 04-26-2013, 08:02 PM   #15
JimVonBaden
"Cool" Aid!
 
JimVonBaden's Avatar
 
Joined: Feb 2005
Location: Alexandria, VA
Oddometer: 49,385
Quote:
Originally Posted by rdwalker View Post
There is a serious side to this - though it is open to all our jokes and sneers in previous posts.

The problem is that dripping oil may coat the rear tire. Then it's "To the Moon, Alice!".

Call me a coward, but I, for one, would never ride with an active leak.


Jim
JimVonBaden is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 03:20 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014