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what is this hole??

By ty151,
in WR400F/426F/450F

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ty151

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That's exactly what it was doing. I got the plug from TT and it's been fine ever since.

:banghead:

Well thanks a lot man....its been bugging me so much cause i couldnt figure it out. The plug is in the mail and should be here in a few days. I dont have to remove the radiator to put it in do i???

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WR_Dave

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No they use a metal cup plug. You will need to carefully tap it out from the inside with a punch and then replace it with the new plug that you will be installing. You may get the old plug out by removing the set screw/bolt and having the plug fall out for you or be able to wiggle it out, but be careful not to gouge or distort the aluminum. WR Dave.

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ty151

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No they use a metal cup plug. You will need to carefully tap it out from the inside with a punch and then replace it with the new plug that you will be installing. You may get the old plug out by removing the set screw/bolt and having the plug fall out for you or be able to wiggle it out, but be careful not to gouge or distort the aluminum. WR Dave.

Where exactly is the set screw/bolt??? And is oil going to drain out when i get the old plug out??

i got the new plug in the mail today and it was just the plug itself. i thought people were talking about a screw that holds it in?? Thanks for the help

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WR_Dave

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In the post that you started this thread with , you have a yellow circle around the "hole" and inside that circle is the set screw/bolt. There may be an ounce of oil when you remove the plug. If this issue is getting to be this much trouble for you . I suggest getting a mechanicaly inclined friend to help you out or pay the price at a bike shop. It really isn't a big deal to repair this problem. :banghead: WR Dave.

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Bullwinkle

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Just loosen that bolt that's at the left side of the yellow circle in your original post, seat the plug all the way in the hole (it should be almost flush), and tighten the bolt back down on it.

As was said before, do make sure all of the old plug is removed. (If it's gone it probably came out all as one piece, but be sure.) A post earlier said that the old plugs were all metal, but that wasn't true for mine. (Possibly Yamaha used different plugs over time.) Mine was a black plastic disk with about a three or 4 mm sleeve, also black plastic. The only metal was on on the flat part of the disk, and then only on the inside. (The side that faced the motor.) Think of a screw off soda bottle cap, with a metal disk pushed into it.

Good luck.

:banghead:

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WR_Dave

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You may have to drill and tap the hole to the next bolt size. Be very careful when doing this to avoid getting metal shavings into the engine. Slow drill speed with some grease on the drill tip usually works. Then tap the hole to the next bolt size ( if a standard thread is the next size use it-make sure to use a fine pitch to get more threads) When tightening the new bolt be very careful to only get it snug not over tight as I think that is what happened to the first bolt. A little blue locktight should help keep it in there and stay tight. Good Luck with the repair , take your time and do it right and you will be back riding in no time. WR Dave.

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WR_Dave

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If the metal is thick enough there you can use a fine thread ,short bolt to hold the new plug in place. The problem with a helicoil in the area you are having problems with is that the helicoil is probably too long for the thickness of the metal. And while you can cut the coils to fit I don't think you will have alot of luck sealing the oil inside the engine as it can travel in the helicoil threads. So yes I do recommend just tapping the hole to a fine thread bolt and use a little blue loctite to seal it and hold the bolt from loosening. Just my .02 with things that work for me when I have these sorts of issues. WR Dave.

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WR_Dave

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http://sosnick.uchicago.edu/tap_drill_size.html

http://www.jeepfan.com/tech/TapThreadSizeChart.htm

Using the charts in the links , it looks to me that the best method would be to use the M8 bolt with 1.25 pitch to replace the M6 bolt that is stripped. So you will need a M8 x 1.25 tap and a 6.8 mm drill bit which crosses to a 17/64 drill bit. Just drill the hole ( straight) and run the threader in and out to restore the threads and then clean any burs off of the inside of the hole bore and insert the new plug and bolt. Blow out any excess shavings and go riding. If your not sure about the drill bit sizing, try a test hole in some scrap metal to see if it is the correct bit to make the threads tight on the bolt and don't forget the blue loctite.:banghead: WR Dave.

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