Can't believe this shit

[SuperDave]

Well I could've asked for anything worse to happenen today.
Was planning on going to Taupo next Friday but looks like this won't be happening at the current rate.

The thread on my sump is fucked and the sump plug won't tighten up.

Now I've heard of helicoils and getting the thread redrilled and stuff but what I need to know is if I will be able to get this sorted in time for the trackday?

Any Ideas? what's the best to get the whole sump off myself and take it in to an engineering place and then put it all back up myself? Is this complicated to do? How long would it take an engineering place to sort the thread out for me? Any places that would be able to do this for me on the Shore next week and quickly?

Thanks heaps in advance, I really don't want to miss this trackday but I might have no choice.

[texmo]

You have to drop the motor out of the bike to get it helicoiled from what im awear. PM loosebruce hes done this before.

[Zed]

That sucks SuperDave, I hope you can get it sorted this week and join us down there at Taupo. Sorry I can't give you any helpful advice on this one.

[SuperDave]

What about just the sump itself? I'll need to take the header pipes fully off to be able to remove the sump. I'm wondering if it's worth the effort taking the pipes off incase I run into another snag.

[SwanTiger]

The thread on my sump is fucked and the sump plug won't tighten up.
Must be a Suzuki thing.


Now I've heard of helicoils and getting the thread redrilled and stuff but what I need to know is if I will be able to get this sorted in time for the trackday?
As far as I am aware it shouldn't take any longer than a day to have it sorted. I'm not sure if you need to take the engine out of the frame like Texmo suggested but I imagine even if you have to it will be possible to have it sorted by next weekend.

[sAsLEX]

You have to drop the motor out of the bike to get it helicoiled from what im awear. PM loosebruce hes done this before.

Nah you should be able to helicoil in situ but might need to lean the bike over a bit to gain access.

Ring an engineering shop, r for that mattera bike shop and see what they say

[TLDV8]

Does it have a removable sump ? (from the engine cases)

[SwanTiger]

Dave, send WINJA a Private Message or wait for him to see this thread, he suggested a good place to me that I could take a head to as the spark plug thread had been screwed. Lesson learnt - don't let your mates put in spark plugs.

[SuperDave]

Does it have a removable sump ? (from the engine cases)

Certainly looks like it. My dad is helping me out, we're taking the header pipes off first and then we'll take the sump off. I've sorta answered my own question was just waiting to see if any one shouted "NO don't take the sump off, that will cause more problems!" or something like that.

The reason I want to get the sump off and take that into the engineering store is cause I don't have time this week to cart a bike to and from an engineering store.

[BNZ]

Give the boys at spectrum a call, they are magicians! :done:

Im sure they will be able to give you some advice on the matter.

[TLDV8]

If that section with the sump plug is removable, it should be an easy fix.

[marty]

either get it helicoiled (20 minute job) or plug welded and re-tapped (an hour tops)

[SuperDave]

Okay after much fussing and tantrum throwing I calmed down and got down to work. Radiator off, header pipes off and out of the way and off came the sump without any trouble.

But here comes the interesting part - is it normal to find stones in it !? :gob:

Me thinks in it's previous life this bike maybe had a moment of sabotage...

Not one stone, but several small stones with a few larger ones!

Okay so now the sump's off means all I need to do is take it into an engineering place and get either the helicoil done or retapped - My question is which one woud you suggest/recommend and why?

Thanks everyone for the advice thus far

Taupo may still be a goer yet! :D

[T.W.R]

Bit of a bitch that happened Superdave, but one mishap has lead to an interesting discovery though (stones) luckily:yes: though the only possible damage would have come from them getting to the sump (from the oil filler plug) not the chance they'd be able to circulate through the engine (the oil is drawn from the sump through a mesh funnel to the pump then through the motor)

Heli-coiling the sump would be the easy option, but because of the thickness of the sump casing there'd be minimal coil actually biting into the casing plus heli-coils are more apt to block casings (where the bolt or stud is wound into a hole not completely through it).

Re-tapping the sump plug hole as is only re-sets the thread, possibility being that would fracture the thread and you'd be back to square one again a few oil changes down the track.

Best option & most permanent would be to have the sump plug hole welded then tapped creating a completely fresh thread

[Smokin]

But here comes the interesting part - is it normal to find stones in it !? :gob:

There are some mongrel buggers around alright, They were probably stoned :dodge:

[classic zed]

I have Time serts which actually replace the whole thread with a steel insert, they are vastly superior to heli coils, I can do the operation in situ for you or if you have the sump off just bring it in takes about 5 minutes for the whole thing. I can do plug threads too without removing the head.

http://www.timesert.com/

Let me know if you need it done:yes:

[SuperDave]

Thanks TWR - just the sorta info I was after.

[TLDV8]

The TL1000 case is the same with the problem being that cut out.A lot of folk do not torque the sump plug up (only around 16.5 ft/lbs) and the threads start to break away starting at the edge of the cut out.
Welding as mentioned sounds like a plan (there are various inserts available also) but consideration would have to be given to filling the cut out even though a little oil would be left in the sump when drained.

Edit..Just spotted Classic Zed's,that is the route a lot of folk take as long as they do not back out,some of the early versions were crap.

[classic zed]

The TL1000 case is the same with the problem being that cut out.A lot of folk do not torque the sump plug up (only around 16.5 ft/lbs) and the threads start to break away starting at the edge of the cut out.
Welding as mentioned sounds like a plan (there are various inserts available also) but consideration would have to be given to filling the cut out even though a little oil would be left in the sump when drained.

Edit..Just spotted Classic Zed's,that is the route a lot of folk take as long as they do not back out,some of the early versions were crap.

I have been using timeserts for the last 10 years, not had one back out yet:yes:

[James Deuce]

But here comes the interesting part - is it normal to find stones in it !? :gob:



I hate to say this but it's been in a gravel trap at some point.

Ex-race bike?

[nadroj]

Just had the same problem with the Busa. The next size up is probably 5/8" so get yourself a 5/8" sump plug from Repco or Supercheap & tap it out to that. There is plenty of meat in the sump for it but you will have too little to go to the next size in metric if you manage to find the next size sump plug in metric. I was advised the thread inserts would come loose due to the slot for oil drainage by experienced engine builders.
Good luck.

[SuperDave]

I hate to say this but it's been in a gravel trap at some point.

Ex-race bike?

Yeah I've known it was raced earlier in it's life since I bought it.
How exaclty do stones get in even it it does go down in gravel? I reckon it was a bit of sabotage via the oil filler cap by another racer haha.

Now to get the damn race fairings to fit in the mean time, tis not as easy as I thought it would be.

[SwanTiger]

Yeah I've known it was raced earlier in it's life since I bought it.
How exaclty do stones get in even it it does go down in gravel? I reckon it was a bit of sabotage via the oil filler cap by another racer haha.

Now to get the damn race fairings to fit in the mean time, tis not as easy as I thought it would be.
Part of the casing is worn away, rocks get in and who ever repairs it doesn't find or think to look for debri? I don't think the biggest of the rocks would fit through the oil filler cap. Give it a go and see if it does.

[SuperDave]

Swanny the filler cap on the Gixxer is pretty big, not like the drinking straw you use to fill up your bike with :bleh: Those stones would easily fit in mine.
Damn race fairings, I wonder if fibreglass has a memory if stored funny for a while?