Drain plug stripped

garage_hacker said:
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...
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The black plastic oil drain plugs that Kawasaki put into some of these engines are a pitiful joke.

Sounds like someone rigged it. Probably attempt to install a larger plug, and then if unsuccessful, a whole new sump, etc. This will mean pulling the engine and a bigger job.
 
The plug on my Kawasaki is plastic set screw you back out to allow oil to flow from the plastic nipple to rubber hose extension that came with mower .

After 50 years of wrenching I found something you’ll need a thread identification set.
Available for$20 on Amazon.

Good luck fixing yours
 

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garage_hacker said:
I acquired a BadBoy Outlaw with Kawasaki FX850-GS15R engine - it's leaking oil heavily from the drain plug.
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Contact a certified Kawasaki repair shop. There was a recall on a production lot for improperly cut threads on drain. Kawasaki replaced customer’s lower crankcase casting where the drain is located. No HeliCoil hacks. Job done right.

If yours is one of the bad lot you should get a free repair.

If shop says, “Never heard of it!” then find another and never return to the first. Local shop was happily doing a couple per week for a long time as Kawasaki was paying a fair rate for the job.
 
2ndkubotain36yrs said:
The plug on my Kawasaki is plastic set screw you back out to allow oil to flow from the plastic nipple to rubber hose extension that came with mower .
Click to expand...
The biggest problem with those is how users will over torque the plastic 10mm drain thing. The way it is designed, tighter will not seal any better than simply closed.
 
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