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Discussion Starter · #1 ·
Hi all -
I recently discovered that someone who had changed my oil in the past had stripped the threads and covered it up by using a heli-coil. I noticed an occasional drop of oil here and there and decided to look into it, which is how I discovered the problem.

In researching what to do about it, I have come across various mentions that using a heli-coil isn't recommended because it could cause a problem with the oil flow? To be clear, I haven't found anything that states this is a definite problem with THIS SPECIFIC model/year, which is why I'm asking for specifics.

I'm no mechanic, but I have a hard time understanding how this could be the case. On the other hand, while inspecting the threads in the casing, it does appear as though there could be what looks like a port or some sort of opening that goes through the threads!

I have seen various recommendations that say tapping the opening to the next size is ok, all the way to you have to replace the mid-section of the housing. I've seen estimates of $1400 to replace the stripped housing. I'm not sure it's a good value to spend that find of money on a 10-year old machine that we get to ride a few times a year. On the other hand, she is a tiny lady and doesn't want to get a full-size machine; this is the perfect size for her.

Anyone KNOW FOR SURE if there is something 'special' about this opening that would preclude using a heli-coil or tapping to the next size bolt?

I've never had a good experience at a dealer, so I'm reluctant to bring it in for an 'honest' opinion.

Many thanks for any info or direction to good information.

Rich P
 

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Can't tap it out oversized. The case there is super thin.

Here's what I did, but I had the engine apart so it was much easier to see exactly what I was doing.

https://www.hondaatvforums.net/forums/honda-rancher/49358-oil-drain-plug-bung-busted.html#post435533

If you have a helicoil in there I'm surprised it's dripping. How far up into there do you see threads when you look after draining?

adding this link that shows the fumoto I actually used.

https://www.hondaforeman.com/130-foreman-500/71918-oil-drain-plug-size.html#post3021473
 

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Hi all -
I recently discovered that someone who had changed my oil in the past had stripped the threads and covered it up by using a heli-coil. I noticed an occasional drop of oil here and there and decided to look into it, which is how I discovered the problem.

In researching what to do about it, I have come across various mentions that using a heli-coil isn't recommended because it could cause a problem with the oil flow? To be clear, I haven't found anything that states this is a definite problem with THIS SPECIFIC model/year, which is why I'm asking for specifics.

I'm no mechanic, but I have a hard time understanding how this could be the case. On the other hand, while inspecting the threads in the casing, it does appear as though there could be what looks like a port or some sort of opening that goes through the threads!

I have seen various recommendations that say tapping the opening to the next size is ok, all the way to you have to replace the mid-section of the housing. I've seen estimates of $1400 to replace the stripped housing. I'm not sure it's a good value to spend that find of money on a 10-year old machine that we get to ride a few times a year. On the other hand, she is a tiny lady and doesn't want to get a full-size machine; this is the perfect size for her.

Anyone KNOW FOR SURE if there is something 'special' about this opening that would preclude using a heli-coil or tapping to the next size bolt?

I've never had a good experience at a dealer, so I'm reluctant to bring it in for an 'honest' opinion.

Many thanks for any info or direction to good information.

Rich P
i'm wondering if just your sealing/crush washer is the source of your leak. your heli-coil shouldn't be a cause of the leak cause you don't rely on the threads to seal anyway. it's all about the sealing washer. and i looked at a bunch of pics and there is no way a port would be going through those threads. wouldn't make sense anyway. so no a helicoil itself shouldn't be a problem.

Can't tap it out oversized. The case there is super thin.

Here's what I did, but I had the engine apart so it was much easier to see exactly what I was doing.

https://www.hondaatvforums.net/forums/honda-rancher/49358-oil-drain-plug-bung-busted.html#post435533

If you have a helicoil in there I'm surprised it's dripping. How far up into there do you see threads when you look after draining?

adding this link that shows the fumoto I actually used.

https://www.hondaforeman.com/130-foreman-500/71918-oil-drain-plug-size.html#post3021473
that's some great info and pics there jeep.
 

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Discussion Starter · #6 ·
Thanks for the replies guys. I suppose the crush washer could have been the cause of the leak, but when I took out the drain plug to change the oil, something didn't look right.



My son is a machinist, so I asked him to take a look. He ended up taking out the coil because it was no good. He then ran a tap through the hole to clean up the threads (I think he went up from a #12 to #14). I installed the new #14 drain plug, but it still leaked a few drops, here and there. With VERY limited opportunities to ride, and one of them almost upon me, I used a nylon washer as a crush washer, and used liquid gasket around the threads of the bolt as I couldn't torque it tight.

The wife and I got to do our weekend ride on ME's Roxbury Trails without incident. But I figured I shouldn't tempt fate for the upcoming season. We tend to do long rides instead of frequent rides.

I guess I'll bring it to this new mechanic I was referred to and see what he has to say. I even read a thread where someone recommended using a shop that could weld aluminum so they could simply drill and tap a #12 hole in a tiny plate and weld it OVER the existing hole. Not sure if that's feasible or fantasy. But it sounds like another possible option.

I'll post back after I get feedback from the new mechanic. And once he has the existing plug out, I'll see if I can get a better picture of the hole to see if there really is anything flowing through that area.

Thanks again.

Rich P
 
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