How to fix stripped drain plug on 2014 KTM 350 SXF

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5/14/2018 4:55 AM

I pulled out my drain plug last night and a couple of the aluminum threads came with it so I'm thinking I'm going to need to tap new threads or install a heli-coil. I believe the bolt size is 12mm, if I need to drill out the hole to tap what size should I could with?

Anyone have recommendations or advice for the best way to fix this? I'm hoping to fix without removing the engine, but haven't checked yet to see if I have enough space so any advice would be greatly appreciated.

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5/14/2018 5:01 AM

There is just not much material to work with in that area of the case. If you attempt to make it larger then it is even worst. Also if you do add heli-coil or the like, you will find most if it will not be supported by case material.
IMO...
Either spring for a new case or take what you have apart and have the case welded and then drilled and rethreaded.

Paw Paw

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5/14/2018 5:11 AM

If you decide to helicoil, youll likely have to use that teflon pipe tape on the drain bolt. As pawpaw said, theres little material there and it likely wont seal.

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5/14/2018 5:27 AM

Thanks for the tips! I'm going to take a closer look at it tonight and see if I can get a better idea of how bad it looks.

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5/14/2018 7:16 AM

Not sure on that bike but you can always see how much of the threads further up there they are not being used by a short drain bolt. Sometimes you can get away with just having a longer bolt.

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5/14/2018 8:16 AM

I'm not sure I would do this myself, but they make an oversize 12X1.5mm plug for automobiles. It is slightly larger and cuts its own threads to maybe a 12.25mm or 12.5mm size. They work on aluminum automobile oil pans, so maybe. I will say I've used them on cars with success.

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Take it to the limit, one more time!

5/14/2018 8:23 AM

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Take it to the limit, one more time!