Hi everyone, new to the forum and my first post.

Just bought a 1995 GS500E, and I did my first oil change on her today.

Now in my typical stupidity, I over-wrenched the oil drain plug the wrong way and stripped her. So the oil drain plug doesn't tighten on the threads 

My question to you guys...what do I need to fix this? Sorry if its a dumb question, I'm a mechnical newbie. Gotta start somewhere!

Thanks in advance.

check to see if the pan or the plug is stripped.

if it's the plug, you can try getting a new one and seeing if that fixes the problem (remember to also get a new crush washer)
if it's the pan, there's: 1) getting a new pan, 2)tap the hold and going oversized with the plug.

not sure what anyone else will tell you, but those are my ideas.

Welcome to the forum! pictures? haha

helicoil

Cookie

the oil pan is aluminum, the plug is steel. I doubt the plug is stripped, if you can tap and get a over sized plug that would be the cheapest way, but that will introduce metal into the oil so watch out. I would recommend getting a new/good-used oil pan and new plug.

My '95 was like that when I bought it.. didn't know.  Not so bad that They just put a rubber washer on it and it holds "good enough."  When I have the extra money I will order a new pan from bike bandit.  You could probably tap it and go oversized.. or tap it and helicoil it.. but tapping stuff is a pain.. (especially upside down under a motorcycle, you'd probably want to take the pan off anyway..)  Best bet is get a new pan.
1: PAN OIL   1038747(477799-001)     $52.89
2: GASKET,OIL PAN   1038636 (477732-001)    $6.70
4: PLUG   1027582  (471288-001)    $3.27
5: GASKET  14.1X18X1.5   1025772  (470153-001)    $0.97  (this one is the crush washer.)

So, if all of your oil pan bolts are okay you're looking at ~$64 + shipping.
I don't know the spec on the oil pan bolts torque for the GS but most oil pan bolts are like 20 INCH pounds (Less than 2 FT pounds.. so be CAREFUL tightening them down!)
The Oil Pan Drain Plug should be just tight enough to crush the washer.. and the washer should be replaced EVERY time.  For $1 each you might as well get a few.. or a decent shop should give you one when you buy an oil filter. 

try using teflon tape on the bolt to see if you can get a better bite until a better fix!!

I have never replaced the crush washer on my plug, it doesnt leak a drop.

Quote from: black and silver twin on June 25, 2010, 08:32:43 PM
I have never replaced the crush washer on my plug, it doesnt leak a drop.

Do you use a copper or aluminum?  I know you don't NEED to do it every time. But, you SHOULD.  Especially for the aluminum ones.  It's a good gauge for how tight the bolt is.  And, a fresh crush every time insures a good seal.  Copper ones can last a lot longer.  The aluminum ones can last too if they never get crushed too hard.  For something as petty as a crush washer.. It's just a good idea to do it.

Quote from: Elijafir on June 25, 2010, 10:12:19 PM

Quote from: black and silver twin on June 25, 2010, 08:32:43 PM
I have never replaced the crush washer on my plug, it doesnt leak a drop.

Do you use a copper or aluminum?  I know you don't NEED to do it every time. But, you SHOULD.  Especially for the aluminum ones.  It's a good gauge for how tight the bolt is.  And, a fresh crush every time insures a good seal.  Copper ones can last a lot longer.  The aluminum ones can last too if they never get crushed too hard.  For something as petty as a crush washer.. It's just a good idea to do it.

I have no idea what the seal is made of, ive never looked that closely at it. Its the original one the bike came with in 2007.

Quote from: pandymai on June 25, 2010, 04:20:40 PM
check to see if the pan or the plug is stripped.

if it's the plug, you can try getting a new one and seeing if that fixes the problem (remember to also get a new crush washer)
if it's the pan, there's: 1) getting a new pan, 2)tap the hold and going oversized with the plug.

not sure what anyone else will tell you, but those are my ideas.

Welcome to the forum! pictures? haha

Thanks for the quick replies everyone. I checked her this morning and I stripped the oil pan. Tell tale sign was the drain plug had crushed bits of alumnium in the threads. Looks like I'm getting a new oil pan!

you can also go to an engine reconditioner and get a helicoil put in, In the GS500 they are the same size as a 14mm spark plug so most places should have one and get it back to you in few hours for about $25.00.

Hint: use a ratchet wrench and  set it to anticlockwise before you get under the bike doing this would this would save a few alloy sumps 

Cheers