Gear case plug stripped

[ryno44]

So I stripped the gear case plug today....what now. Thinking about cutting a bolt down and re-tapping the case a bit bigger. Any suggestions? Not much room for error as far as clearance goes next to the chain. Would like to seal it up and not use the plug again, what type of sealer should I use.
Thanks in advance.

 

[Ron]

Unless you pulled all the threads in the case, I'd clean up the threads with a tap, clean the surfaces with carb cleaner and reinstall the bolt using good silicone, maybe a dab around the bolt on the inside after it's installed. Use tub and tile or a good silicone gasket sealer.
A more permanent job (& stronger) would be using JB Weld instead of silicone. Get the surfaces clean for a good job
If threads are pulled or for a better job there is always the heli-coil threaded insert-would be better than trying a new bolt.

So I stripped the gear case plug today....what now. Thinking about cutting a bolt down and re-tapping the case a bit bigger. Any suggestions? Not much room for error as far as clearance goes next to the chain. Would like to seal it up and not use the plug again, what type of sealer should I use.
Thanks in advance.

 

[ryno44]

The threads are still pretty good on the plug. The threads in the case are shot. Where could I find heli-coil insert? Auto parts store?

 

[diamonddave]

Go to Napa and purchase a "1" oversize 14mm self tapping oil pan drain plug. The original threads are 9/16X20. I've now used these on 4 polaris chain cases. Work very well.

The part number for the self tapping drain plug from NAPA is 704-1362 and lists for $3.67. It is a 1 size over 14mmX1.5.

Tapping to a larger size is not possible due to the casting ridge that is just to the inside of the drain hole.

 

[rmk727]

Diamond Dave is right on I've done it several times with success everytime, infact now when changing oil I just do it the old way and clean the mess

 

[EricW]

X3 on what Diamond Dave says. I keep a couple extra in the shop and they are always being used by riding buds. Weak spot for sure. Good luck. EW

 

[ryno44]

Thanks for the tip DiamondDave.

 

[sledhed]

Go to Napa and purchase a "1" oversize 14mm self tapping oil pan drain plug. The original threads are 9/16X20. I've now used these on 4 polaris chain cases. Work very well.

The part number for the self tapping drain plug from NAPA is 704-1362 and lists for $3.67. It is a 1 size over 14mmX1.5.

Tapping to a larger size is not possible due to the casting ridge that is just to the inside of the drain hole.

Diamond Dave is right on I've done it several times with success everytime, infact now when changing oil I just do it the old way and clean the mess

X3 on what Diamond Dave says. I keep a couple extra in the shop and they are always being used by riding buds. Weak spot for sure. Good luck. EW

Did the same thing with self-tapping plug from NAPA, forgot which size though, thanks for the reminder, in case I strip out my 800. Very frustrating, but there are almost no threads on that plug and it threads into aluminum, so a little cross-thread or a little too much torque and you are toast. This was on my wife's D7 right after she bought it, so double-oops. Siliconed it to boot, and from there on out I just removed the cover. I was having water contamination problems in her chaincase so I had to keep changing the oil, ended up replacing the drive shaft seal which fixed that problem.