Drain plug stripped

garage_hacker

garage_hacker

Member
I acquired a BadBoy Outlaw with Kawasaki FX850-GS15R engine - it's leaking oil heavily from the drain plug. I purchased a Flexible Oil Drain hose that supposedly fits Kawasaki FX models hoping to do a quick swap. Today, I washed the machine clean and removed the drain plug. The flexible drain hose threads are not lining up with those on the engine crank case. What's worse is that the plug that was in there does not want to go back in - plug doesn't look OEM, it looks like it's something that came from a hardware store. Looks like I got myself a job, with 6-8 bananas of difficulty. Does anyone know what the threads are on that engine drain plug? I may have to re-tap it or chase it or God knows what.

It looks like the flexible hose has an M20 x 2.5mm thread - using the metric thread gauge and a caliper. Can't tell if it's pipe thread or not. Oh what horror...
 
Kawasaki FX850-GS15R > FX850V-GS15 does (did have) M20 x 2.5mm [92066-0774] plastic drain plugs. Normal metric course threading. If steel plug square drive then someone most likely stuck in SAE pipe threads. I see this several times a year where SAE is cross thread into Metric holes by DIYers and vice versa. Now there metal aftermarket metric plugs, some even with magnets.

Normal plus sometimes black sometimes gray.
1772349622128.png

It is probably better to just replace the crankcase cover (oil pan) [49015-0730] as they list for around $200 new plus an oil seal, 2 drain plugs, and RTV.
 
I have no idea what the specific engine's oil pan looks like, but one possible thing to look into is: Find an oil drain plug slightly larger than the current hole. Drill out the hole to the size required to tap the larger hole properly for the new larger drain plug. Putting grease on the drill bit will catch most metal chips and you can always wash some oil (new or used) through the engine to flush out any chips that may end up in the oil pan.
 
I would not add anything that did not come factory to the engine. Especially an oil related item. These are mostly air and oil cooled engines. Lose the oil and she is done. Bad enough most people don't even check the oil level. Should be checked PRIOR to every mow. Your mower so install what you want.

Another thing on those hose extension kits. The oil drains painfully slow. I doubt if you get all of it out of the sump. These mowers get bounced around and things loosen up.
 
StarTech said:
Kawasaki FX850-GS15R > FX850V-GS15 does (did have) M20 x 2.5mm [92066-0774] plastic drain plugs. Normal metric course threading. If steel plug square drive then someone most likely stuck in SAE pipe threads. I see this several times a year where SAE is cross thread into Metric holes by DIYers and vice versa. Now there metal aftermarket metric plugs, some even with magnets.

Normal plus sometimes black sometimes gray.
View attachment 72735

It is probably better to just replace the crankcase cover (oil pan) [49015-0730] as they list for around $200 new plus an oil seal, 2 drain plugs, and RTV.
Click to expand...
I can’t count the number of chainsaws that i get in where they lost a screw and they just cranked in a SAE screw or a sheet metal screw into a $1k saw.
 
If you install a tapered thread metal plug and turn it in too tight it WILL CRACK/SPLIT THE ALUMINUM BLOCK. A thread tap will also do the same.
If using a metal tapered plug add at least 3 wraps of teflon tape first then just get it snug with a limp wrist..

I suspect that is one reason they used a plastic plug with a o-ring so as to not overtighten and crack the block..
 
slomo said:
Dude. it's all about pipe dope these days. Teflon is so 1982 LOL. :D
Click to expand...
Probably/maybe because pipe dope is a no brainer does not have to be applied/wrapped in the proper direction on the threads and less likely to drop the brush when applying. I've won quit a few bets/lunches with grasshoppers by betting who would be the first one to drop a roll of teflon tape during application. If you say you have never dropped a roll of teflon tape and see it unspiral you have never used it or you are a liar.:rolleyes:
I've also noticed that a fitting USUALLY has to be somewhat tighter when using pipe dope vs teflon tape.when subjected to hot oil.
 
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