Stripped Oil Pan Drain Plug..Best plan of attack?

[fury8793]

Well, its official..nothing will save my stripped drain plug hole in my oil pan. I just attempted to try different techniques to get it to plug the dripping to no avail, the PO has officially fubarred me. So, I feel that there are several options that I can do here and I would like to see what all y'all have to say about my options or have any additional ones that could possibly help.

Is it possible to keep the pan on the bike for any of this or is best to take it off so there's no metal shavings to worry about? Only reason that I ask is because I could take some heat to my header bolts but I'm still a little scared of them snapping off..

A) Heli-coil it with a slightly larger thread

B) Drill and tap a new hole, install a Fumoto

C) Cringe at taking my header off,drop the old pan, buy a new one, Paint it up nice, install a fumoto, install new pan.

Any other options out there guys?

Here's the oil pan I found on ebay, I feel it would be a good buy.

http://www.ebay.com/itm/Oil-Pan-Engine-katana-600-02-2002-Gsx-600f-98-99-01-03-04-05-/331554946321?hash=item4d3236fd11&vxp=mtr

[shpielers]

If you're going to drill/tap a larger hole I'd recommend pulling the pan anyways so you don't end up with metal shavings in there. They have a way of killing bearings real quick.

[arsenic]

I would pay money to see you drill a tap a new drain plug hole with the oil pan still on the bike. I'm sure it's possible, but it would be a GIANT pain in the ass.

[fury8793]

Alright, so what's the best way of getting the bolts for the exhaust off then without them snapping off?

I knew I couldn't get around not dropping the pan but my father thought otherwise, oh well. Stubbornness comes with age I suppose.

[arsenic]

Heat and penetrating fluid, like PB Blaster or Kroil. If they are gonna snap, they are gonna snap, there's not much you can do. If they do snap, I've had good luck soaking them in Kroil and they come out with pliers. When you install them, use high temp anti seize. That way you won't have to worry next time.

[ZookRick]

When I stripped my oil pan plug on my GS, I went to Napa and got an oversize plug that you screw in and it makes its own threads. Not a perfect solution, but works until you can find a better solution.
This is what it looks like:

http://www.ebay.com/itm/Dorman-65409-Oversize-Type-Drain-Plug-/221625560342

[maniac1886]

No matter how you cut it, that pans gunna need to be dropped. Better let the header bolts start soaking in PB now. Be care with the header bolts if they are that bad. Use the right tool, use quality tools, and use a breaker bar. I was scared when I pulled mine off my 97 but they came pretty easy, they must have been taken off before.

[fury8793]

That's what I figured, mine as well go get some PB blaster now and start soaking the bolts in it before I go ahead and snap then off. Kroil? I can honestly say I have never heard of that, Arsenic..

[arsenic]

google it

[fury8793]

I can always rely on the KatRiders very blunt smart a$$.

[arsenic]

[41 Redhawk]

I can always rely on the KatRiders very blunt smart a$$.

In fairness he could have done this:

http://lmgtfy.com/?q=kroil

[92xjunker]

Kroil is the best shit on the planet, they are not longer making it under that name. It's now penetroil. Nu-Calgon bought them out. Still awesome stuff.

[shpielers]

In fairness he could have done this:

http://lmgtfy.com/?q=kroil

I love lmgtfy!

On a more serious note, I'm going to order some of it and try it out. I'm going to replace the 23year old exhaust gaskets on my 1100 to fix an exhaust leak. Those bolts aren't going to come out easily.

[retcol]

I did the same as zoorick, bought an oversize bolt from my local autozone store that was meant to replace a stripped oil pan bolt. Worked like a charm and I've never had a leak with it. Much cheaper than a new pan.