I messed up -- Overtightened and cracked the bung hole - Suzuki GSX-R Motorcycle Forums Gixxer.com
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 24 (permalink) Old 05-03-2018, 08:21 PM Thread Starter
Provisional Novice
 
Join Date: Feb 2010
Location: Boston
Motorcycle: 2007 GSXR750
Posts: 161
Exclamation I messed up -- Overtightened and cracked the bung hole

Jesus, I messed up big time. I was changing my oil, which I've only done once before. I thought there was a very tiny leak so I tightened the nut that releases the oil on the bottom of the engine. I ended up way over tightening it and it cracked the bottom of the engine.

I have no idea what to do now. I know this is a monster f*ck up but has this happened to anyone before?
Attached Thumbnails
Click image for larger version

Name:	0503182104b.jpg
Views:	17
Size:	34.9 KB
ID:	547289  
dompel is offline  
Sponsored Links
Advertisement
 
post #2 of 24 (permalink) Old 05-03-2018, 09:02 PM
Amateur
 
Join Date: Oct 2014
Posts: 342
Garage
Re: I messed up -- Overtightened and cracked the bung hole

It sucks, but not the end of the world. You can find used oil pans on ebay for about $80-$100. Al;ways use a new crush washer when changing oil, and a torque wrench.
b3w4r3 is offline  
post #3 of 24 (permalink) Old 05-03-2018, 09:04 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Ah Man,

You really made a rookie mistake but this is how you learn. Drain plug only needs to be snug against ring gasket which compresses making seal.

not the end of the world. lol ^^

Welding would be hack, you need a new oil pan..
look for some on e-bay . ^^ lol (sorry we posted at the exact same time)

Search for 07 gsxr 750 oil pan, and study what the part looks like. It bolts on with a bunch of 8mm bolts and may have been where you leak was coming from as over time they get loose. make sure you get new gasket and make sure drain plug has one to. ^^

I have a friend with a K5...he complained of poor shifting so I went over to take a look. ...well the chain was so tight I wanted to hang him from a tree ...then, when I went to adjust it for him, the rear axle nut was so tight, needed a breaker bar to loosen. Because of this his bearings were shot and the wheel barely rolled.

If your not sure, follow torgue specs in service Manuel.

Last edited by Gixan; 05-03-2018 at 09:23 PM.
Gixan is online now  
Sponsored Links
Advertisement
 
post #4 of 24 (permalink) Old 05-03-2018, 09:14 PM Thread Starter
Provisional Novice
 
Join Date: Feb 2010
Location: Boston
Motorcycle: 2007 GSXR750
Posts: 161
Re: I messed up -- Overtightened and cracked the bung hole

I think one of the problems is I didn't have a drain plug washer/gasket -- that and I didn't use my torque wrench. That's what I get for not googling around for the torque spec...

Honestly guys I'm pretty scared of this repair. A lot of people on the forums I've been searching for the last hour have been saying I need to drop the engine or cut parts of the bike to get the whole oil pan off. I guess there is some plate that is keeping it in and to access the bolts for that plate, the engine has to come out. I can barely change my goddamn oil...
dompel is offline  
post #5 of 24 (permalink) Old 05-03-2018, 09:31 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

If this seems a scary job for you, I recommend you do not do it yourself.

Do tell what forums told you that you need to "cut" parts or drop motor lol.
Gixan is online now  
post #6 of 24 (permalink) Old 05-03-2018, 09:44 PM Thread Starter
Provisional Novice
 
Join Date: Feb 2010
Location: Boston
Motorcycle: 2007 GSXR750
Posts: 161
Re: I messed up -- Overtightened and cracked the bung hole

Quote:
Originally Posted by Gixan View Post
If this seems a scary job for you, I recommend you do not do it yourself.

Do tell what forums told you that you need to "cut" parts or drop motor lol.
Well there's this dude:

This dude dremelled and drilled them out: k6 600 oil pan change (pics included) - GSXR.com
dompel is offline  
post #7 of 24 (permalink) Old 05-03-2018, 09:51 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

^^ Dam ....So sorry I didn't know !

that"s fucked up.
Gixan is online now  
post #8 of 24 (permalink) Old 05-03-2018, 10:39 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Fuck..I can't believe what a PITA they made this for the average DYIer

Studying the Video, don't think the guy needed to remove motor mounts to shift engine for bolt removal.

He maybe could have taken dremel with cutting wheel and cut the heads of the bolts off...there seemed to be enough room to do so ?

fk
Gixan is online now  
post #9 of 24 (permalink) Old 05-03-2018, 10:46 PM Thread Starter
Provisional Novice
 
Join Date: Feb 2010
Location: Boston
Motorcycle: 2007 GSXR750
Posts: 161
Quote:
Originally Posted by Gixan View Post
Fuck..I can't believe what a PITA they made this for the average DYIer

Studying the Video, don't think the guy needed to remove motor mounts to shift engine for bolt removal.

He maybe could have taken dremel with cutting wheel and cut the heads of the bolts off...there seemed to be enough room to do so ?

fk
That's what i thought too but reading the comments in the video, it sounds like you can't do that. I don't fully understand why though.
dompel is offline  
post #10 of 24 (permalink) Old 05-03-2018, 11:02 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

edit..

Let me read the reviews

Last edited by Gixan; 05-03-2018 at 11:09 PM.
Gixan is online now  
post #11 of 24 (permalink) Old 05-03-2018, 11:13 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

There were hardly any.

Naw , all the guy had to do was cut the bolts ...for whatever reason he thought he had to remove them intact.

you can do this..get dremel and large cutting wheel or mini metal saw
Gixan is online now  
post #12 of 24 (permalink) Old 05-03-2018, 11:18 PM
Soberz again
 
Carnage's Avatar
 
Join Date: Jan 2001
Location: was Boston, now Orlando
Motorcycle: 2006 GSX-R1000
Posts: 14,896
Garage
Re: I messed up -- Overtightened and cracked the bung hole

17mm and 17lbs. You won't do that again.
Carnage is offline  
post #13 of 24 (permalink) Old 05-03-2018, 11:45 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Oh wait lol,

I see the problem with that portion of the frame that hides and is in the way of that one screw lol.

That's fucked also. His solution was reasonable but what a pita !

Here a clear pic of the fker for sale on ebay.

This is now my Life.
Attached Thumbnails
Click image for larger version

Name:	s-l1600.jpg
Views:	7
Size:	147.8 KB
ID:	547305  

Last edited by Gixan; 05-03-2018 at 11:59 PM.
Gixan is online now  
post #14 of 24 (permalink) Old 05-03-2018, 11:55 PM
You should listen to me. No, seriously, listen to me.
 
Join Date: Oct 2008
Location: Santa Barbara
Motorcycle: Blue 2006 GSX-R1000
Posts: 7,518
Re: I messed up -- Overtightened and cracked the bung hole

I have no knowledge of the idiosyncrasies of 600/750 but some of the following from the 1000 side may help.

You're definitely not the first. I'm used to posts where the threads strip but the design of the 600/750 pan apparently causes them to crack instead. That's unfortunate because it effectively rules out a thread insert repair. Other things may additionally go wrong during the fix. A good example of that is here where the thread insert wasn't his biggest problem.

That annoying plate first appeared on 1000's in K9. See this. I didn't understand what it was about then but now suspect that it's associated with catalytic convertor exhausts (no idea why it needs seven screws). If I'm right, you could leave it off if you've removed your converter. Alternately, cutting the bolts and replacing them with shorter sounds doable. But I cringe at cutting off part of the frame as was done in the video above.

Here and here are some others from the 1000 forum. There are still more.

I changed from the Suzuki drain plug and washer to an aluminum plug and Stat-O-Seal as is described here. Much less tightening torque is used. But it's important to secure the plug with safety wire as shown.
BillV is offline  
post #15 of 24 (permalink) Old 05-04-2018, 12:22 AM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Its about time Bill lol,

post 29 on this link you provided was good https://www.gixxer.com/forums/238-09-...se-help-2.html.

I still think cutting would be faster but I would need the bike right in front of me to determine what to do about avoiding cutting frame "Lobe" lol

If you had to get it out clean, no big deal really, just time consuming.

fk
Gixan is online now  
post #16 of 24 (permalink) Old 05-04-2018, 12:32 AM
You should listen to me. No, seriously, listen to me.
 
Join Date: Oct 2008
Location: Santa Barbara
Motorcycle: Blue 2006 GSX-R1000
Posts: 7,518
Re: I messed up -- Overtightened and cracked the bung hole

Another possibility would be to go through the hassle of "properly" removing the plate and then convert the four holes along its rear to slots so that all you'd have to do is remove the front three bolts, loosen the rear four, and then slide the plate forward and out. Some washers on the four bolts might be appropriate.

Poor design in the first place though.
BillV is offline  
post #17 of 24 (permalink) Old 05-04-2018, 12:48 AM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Quote:
Originally Posted by BillV View Post
Another possibility would be to go through the hassle of "properly" removing the plate and then convert the four holes along its rear to slots so that all you'd have to do is remove the front three bolts, loosen the rear four, and then slide the plate forward and out. Some washers on the four bolts might be appropriate.

Poor design in the first place though.
Or a great one lol.

Unless one has decent mechanical skills, requires shop technician to remove, and would be a lengthy job=dollars for MC Mechanics.

Maybe a fail safe device , possibly required but ill conceived by DOT to limit oil contamination in case of catastrophic failure ? no? lol

Last edited by Gixan; 05-04-2018 at 12:50 AM.
Gixan is online now  
post #18 of 24 (permalink) Old 05-04-2018, 09:07 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Op,

I've been thinking about this all day, and it's not even my bike lol.

It's got to be miserable for you cause as you said, if it's a struggle just to change the oil, this will be beyond your skill set. There are various ways it can be done..example, one of the links had a dude that made his own special tools...but there is more to it:

Getting the bike in a proper position to work on.

Removing parts , body panels , exhaust, etc..that you may have no prior experience doing?

Installing the pan itself with gasket and using proper tightening sequence of fasteners.

None of it hard unless you have never done before..

If you don't DIY, you will need to load it up and deliver it to repair shop and possibly get raped on labor costs....or..maybe an honest,experience mechanic will come forward and tell you they have there own special way of doing it that may be affordable...ask around
Gixan is online now  
post #19 of 24 (permalink) Old 05-05-2018, 11:21 AM Thread Starter
Provisional Novice
 
Join Date: Feb 2010
Location: Boston
Motorcycle: 2007 GSXR750
Posts: 161
Re: I messed up -- Overtightened and cracked the bung hole

Quote:
Originally Posted by Gixan View Post

If you don't DIY, you will need to load it up and deliver it to repair shop and possibly get raped on labor costs....or..maybe an honest,experience mechanic will come forward and tell you they have there own special way of doing it that may be affordable...ask around
Thanks man. I appreciate the advice. I'm asking around for quotes and am hearing between $400-650 to get this replaced. At this point, if I can find way to deliver it to a shop on the cheap then I'll be satisfied. Times like this I wish I had a pickup.
dompel is offline  
post #20 of 24 (permalink) Old 05-05-2018, 08:26 PM
Amateur
 
Join Date: Feb 2002
Location: Los Angeles
Motorcycle: 03 GSXR 1000
Posts: 622
Re: I messed up -- Overtightened and cracked the bung hole

Quote:
Originally Posted by dompel View Post
Thanks man. I appreciate the advice. I'm asking around for quotes and am hearing between $400-650 to get this replaced. At this point, if I can find way to deliver it to a shop on the cheap then I'll be satisfied. Times like this I wish I had a pickup.
10-4

So you will need to pay someone to transport it which will add to the costs,fk.

This may sound hack but, you could probably getaway with riding to repair shop.

Check that the crack is only in that one place...and that the drain plug still follows the threads then comes to a stop. Get gasket, hand tighten.

If you are not in a hurry, put some cheepo weld paste on the crack and let dry for additional safety.

wrap some tinfoil around the pan to catch any drips.

Fill bike with oil but much less than normal.

Test ride for a few minutes, keeping revs low.

Check leakage amount, if OK...

Ride it gently to repair shop ?
Gixan is online now  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Suzuki GSX-R Motorcycle Forums Gixxer.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome