Maintenance & Technical > KX500 Original

KX5 drain plug repair

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KXsidecar:
Hey all,

I have a '91 KX5 engine that took a rock to the drain plug. Broke the drain plug and threads completely out. Is it possible to repair the case or do I need to replace? I can't post pic yet. Soon I will have enough post and will post a pic.
I loved this motor and want to run it again.

Thanks for any help,

KXsidecar
or Mike the Tall

Friar-Tuck:
  Mike,
Cases are pretty pricey new, you may be able to find a decent used set,
But have you considered "Helicoil" or the like?
    There are several other "JB Weld type repairs. Usually a two part epoxy type deal.
 I think that would be great as a band-aid to finish a race however welding and re-tapping or helicoil type insert would be the best bet.
 (I am no expert by any means, but I have used the helicoil on a friends stripped drainplug and held great for three years and then the guy sold the bike.)
 http://www.youtube.com/watch?v=RFYa6sjhh_E&feature=related

http://www.amazon.com/Helicoil-5334-14-Thread-Thread-Repair/dp/B0002SRF4O

http://www.youtube.com/watch?v=RvmL0pEphQI
http://www.timesert.com/

cbxracer30:
I've already had nickle size holes repaired in sets of cases. You need it find someone in your area thatis very skilled with a tig welder. This person should be able to fill the hole right in, but you will have to retouch the area with a file and or retap the threaded hole. For best results you should split the motor , the case welds best when its all cleaned up.The last time I priced cases ,and you must buy them as a set they were over $300. and that was at least 4 yrs. ago

barryadam:
Mike,

Where are you located?  If you need a guy to weld repair that in S. California, I can give you the name of the guy who did mine.  He was in Vista / Escondido area.

Barry

KXsidecar:
Thanks for the responses,

The heli coil is not an option. The rock(not sure it was a rock) busted out almost all the threads. I went to remove drain plug and the case/drain plug threads came with in multiple little pieces. All that is left is 1/4 of thread on 1 side and a jaged hole. It would be easy for some one to weld if I didn't need to drain oil again. I am thinking replacement cases are the only option.
Are all cases the same from year to year? Should I replace as a set? Are case halves matched sets?

I have never had my lower ends apart so forgive the dumbass questions.

Barry I am in Lost Angeles area.

Thanks for your help,

Mike

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