polishhawk

Hey guys,
I bought a 97 foreman that's in great shape and runs great, but when changing oil; I noticed the tapped hole for the drain plug must have been re-tapped to a larger size. Anyways, it will not seal because it is crooked. Because of this the crush washer will not seal on one side of the case. Any suggestions? I also noticed there is a perfect cutout of the thread in the crankcase (does not appear as a break)...is that normal? Any suggestions?
I was thinking if I went to a non-flanged bolt, and used a new crush washer, I may have a better chance of getting a seal.
Anything out there for an easy fix?

Thanks guys

rich450es

welcome to the forum !
i would try the new drain plug gasket 1st ......if that doesnt work you can try to drill and retap it .

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lop3r1

all i can think is that you'll have to drill, tap, and find a bigger plug. then you gotta deal with the metal shavings.

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polishhawk

i hear ya, but what really sux is that the tapped
hole is crooked, so i am going to have a helluva time drilling it straight...will wanna follow the hole

Steve07

How far out of square is it?

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'87 TRX70
'03 TRX90
'03 TRX350FM
'08 TRX420FM - Warn XT25, 25" Mud Bugs, Moose hand/thumb warmers

polishhawk

probably 2-3 degrees... i can see the crush washer is not seated tight on one side of the case. was going to try turning down the crush washer to a smaller diameter along with using a bolt with a smaller head. this would at least minimize the inclination because i would bottom out the other side not as soon. it is a slow leak, but i hate leaks.

Steve07

Is there any point thinking about grinding down a washer or machine bushing the correct diameter to esssentially make a beveled spacer? It would take some patience, but it should just about sit under the crush washer and stay put while you tighten. Also the possibility of a nylon washer or some other malleable plastic that might deform enough to seal under the crush washer? Be hard to get it to stay tight perhaps though. It isn't ideal cf. redoing the entire drain, but it comes down to what the machine is worth for fuss...

__________________
'87 TRX70
'03 TRX90
'03 TRX350FM
'08 TRX420FM - Warn XT25, 25" Mud Bugs, Moose hand/thumb warmers

Kipes

Or you could try using 2 crush washers, that might help.

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2006 Foreman 4x4 500s
Powermadd handguards
2.5 Warn winch
2" Perfex long travel lift kit
High Lifter springs
26-12-12 Executioners on rear
26-10-12 Executioners on front
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Replaced the stock silver engine covers and front skid plate with 07 camo black and painted front brush guard black
2005 Rancher 350ES 2wd
2001 Polaris 325 Trailboss 2wd

bigred_foreman

if you have to drill it dip your drill bit in grease to help prevent filings.

Kipes

Or put a thick o-ring around the drain bolt.

__________________
2006 Foreman 4x4 500s
Powermadd handguards
2.5 Warn winch
2" Perfex long travel lift kit
High Lifter springs
26-12-12 Executioners on rear
26-10-12 Executioners on front
Douglas Rattlesnake rims
3rd Headlight switch
Moose Heated Handgrips and thumb warmer
Garmin Legend gps
Replaced the stock silver engine covers and front skid plate with 07 camo black and painted front brush guard black
2005 Rancher 350ES 2wd
2001 Polaris 325 Trailboss 2wd