torn sump plug

[David B]

I have brought a Voyager 1200 over to Australia, they are not that common here and it always gets a lot of lookers & questions about the bike. I absolutely love it.
The other day I ran it out of our Toyhauler & somehow bottomed out, tearing out the sump plug.
It has torn out a small part of the flat machined face that the plug seals against.
There is still a fair portion of thread inside the sump. Apart from cleaning up one heck of a mess on the concrete I have done nothing else.
Any help or suggestions would be very welcome

[triton28]

David B;
You could have the area welded and rethread the hole, one option but difficult to dress up the weld to not leak.
Instead, the best option would be to contact Carl Leo, voyagerparts@bellsouth.net , and see if he has a good one, and the associated gaskets, seal, etc., which you could purchase. Carl is a great person to deal with and very knowledgeable about Voyagers.
As well, there are used ones on eBay Motors, under the search heading "Kawasaki voyager 1200", such as eBay item # 131384203804. This isn't the only one, just the first one I saw. I would advise questions to the seller about the condition of any used item on eBay.
Good luck down under.
Dave

[David B]

Thanks for your advice Dave. I was thinking it would be a replacement job. Looks like we live at opposite ends of the globe.

[kjsett]

Thanks for your advice Dave. I was thinking it would be a replacement job. Looks like we live at opposite ends of the globe.

Just went through that process a few months ago.
You will need to pull the exhaust - pan won't come out without doing so.
I recommend acquiring the parts and change while at it (because i had to , they flatten):
The O'ring seals for the coolant manifold and any radiator hoses that look old (the hose clamps might need changing too, i had 2 come apart). I also changed the radiator cap while at it. Carl also recommended (and sent me) the 4 exhaust seals (brass).
This is a good time to poke around under the fairings to see if anything needs tightening and such. I installed two Wolo Air horns while working on it (one on each side with relays to fused battery). I had an incident where a car cut me off and there was no response to my stock horns. Since then I had another where a car started coming across real close so i gave them a warning (they jumped back into their lane LOL ).
I took lots of pictures so I could get it all back together correctly. I changed all the lower hoses (NAPA auto parts had what i needed).
Good luck - oh, I would deliver parts personally and help for an All expense paid trip.
Ken

[richardb, austin]

Another possibility is this: http://www.timesert.com/" onclick="window.open(this.href);return false; - it's a lot like a helicoil only better. If the damage is slight enough to allow this. It's quite expensive but you don't have to pull the exhaust, etc. It worked for me. Only downside is that I can't torque the drain plug to my satisfaction. "The Count" (on this forum) can explain the process better than I.

[Mr Jensee]

If the bolt is just sheared off, remove the pan and get an easy out, drill out the middle of the plug and unscrew it using the easy out. Then if the threads are not damaged just replace the plug with a new one.

[joemaniaci]

I changed my oil pan because Carl highly recommended doing so. Good enough for me, wasn't too bad, but it is a bummer that the exhaust was completely in the way. Just make sure all the oil lines get their brass washers back on them when you put it all back together. I now have a spare.