F%$# it, Stripped sump tread. :-(

First topic message reminder :

So I dropped the old oil out today and as luck would have it, near all of the alloy tread from the sump plug hole came out too.  
I'd say that the previous owner had semi stripped it, or fully stripped it and used some type of tread fix.
It's just pulled the tread out like it was only glued in.  

So, Any ideas on how to fix it???????

Like  barry_mcki said, tap around the edge, usually a "sharp crack" will break the seal. Make sure you have  all of the bolts out, try and avoid trying to prize it apart or hitting anything in between the mating surfaces, the will often damage the surface and/or warp the sump

Thanks for the additional advice.

So I take it then that you're saying no to using the scraper? 

I gave it a good crack in a few spots this morning but didn't appear to make any difference. It's so tight that in most places you can't even see a join line, and in other parts I'm not sure that what I'm seeing actually is a join line. And as mentioned previously, there are only a few places you have any hope of getting to with the mallet and/or block of wood.

There's no way you can tap all around the seal unless you take a lot of stuff off the bike. I'm trying to avoid taking the headers, pipes etc., off. The oil sump looks like it's designed to slide out the left hand side of the bike. Might be wishful thinking though on my part. Hoping the Haynes Manual arrives soon and has more information on how to do it.

I just found this parts schematic, there doesn't appear to be any dowels so it should "break the seal' by tapping the pan sideways

Thanks for this mate.

This appear to show 15 bolt holes while the Suzuki Manual shows 14.

Am I counting something that looks like a bolt hole but isn't, or is there another?

That diagram looks like 15 holes to me, I'll duck out and see if I can count the bolts on mine, maybe you still have one in

The Parts Manual list 16 bolts, have a look in the centre of the pan.  

It also looks like the oil pump and pick-up comes down into the well of the sump, so you won't be able to take the pan out directly sideways, it's going to need to come down a bit to clear these parts.

looks like you've still got 2 more bolts to find. Even if it has to be lowered to clear the pick up etc you still may have to give it a sideways tap to break the gaskets seal, I couldn't be 100% sure looking at mine with all of the pipes etc in the way

The Workshop Manual might be missing a couple, I think there are two more here in the red circles:



I haven't gone out to check mine yet, this is what I can see from the different images.

I think we've found the problem, additional bolts to undo.

Thanks for the great support everyone.

I'll see what I can find tonight and let you know how it goes.

Will be interesting to see what the Haynes Manual has when it arrives.

Haynes Manual has arrived.

No process for taking off the sump, just a photo and text saying to remove the bolts.

However, on the next page there is a process for reattaching the oil pan. That photo is much clearer and it looks like there are 15 bolts. Will be able to take a better look when I get access to a magnifying glass.

Yep, There are 16 bolts!

Once the headers & hoses are out of the road. I used my Tex screw runner with 8mm socket to get all 16 bolt off quick smart.

Hopefully the helicoil go's in tomorrow.

Ok, The Heli coil is in and the old silicone gasket removed. 


New thread 

I rinsed out the pick up with fuel



and ended up with a rock and silicone gasket form it 

Bits of silicone gasket that Suzuki use on the sump that I wash out of the oil pick up.

The clean up job was easy.

Nowwwwwwwwwwwwww, time to start putting it back together.

Reardo wrote:

What are we looking at here????

madmax wrote:What are we looking at here????

Bits of silicone gasket that Suzuki use on the sump that I wash out of the oil pick up.

Reardo wrote:

madmax wrote:What are we looking at here????

Bits of silicone gasket that Suzuki use on the sump that I wash out of the oil pick up.

Ok, so is that a container with the oil in it as well, or what you washed it with?

How did a rock get in there?  Someone dropped it in the oil filler?

madmax wrote:

Reardo wrote:

madmax wrote:What are we looking at here????

Bits of silicone gasket that Suzuki use on the sump that I wash out of the oil pick up.

Ok, so is that a container with the oil in it as well, or what you washed it with?

What I wash it in mate, Petrol.

kewwig wrote:How did a rock get in there?  Someone dropped it in the oil filler?

If you work it out, Please tell me! lol
PS he has no kids either.

I guess with the easy remove oil filler, anyone can drop crap into the oil