Rear diff drain bolt stripped??? - Suzuki ATV Forum
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post #1 of 8 Old 06-17-2019, 10:05 AM Thread Starter
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Rear diff drain bolt stripped???

A tad worried. I changed out the rear diff fluid yesterday, and when I went to put the drain plug back in I was tightening it up, and all of a sudden it went soft like I'd stripped it. I wasn't cranking on the thing, just tightening it up prior to adding new fluid.

I was afraid to take it back out so I left it as is. Filled the diff with oil, then rode around the back 40 a few laps. It's not leaking, but if I did actually strip the bolt, or worse yet the housing, just how screwed am I? Whole new diff required, or is it tap-able? Would hate to have any shavings in there...

Oh yeah, it's a 2014 Kingquad 500.

Thanks in advance for any input!
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post #2 of 8 Old 06-17-2019, 11:39 AM
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If you don't want to worry about the shavings possibility .....

If it's not leaking, I would just leave it alone and get a tool that removes the grease with a flexible tube with vacuum. I've seen them for removing oil from a car so it would be a snap for the small amount of diff fluid.

And keep an eye on it for leaks.

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Last edited by TCIII; 06-17-2019 at 06:08 PM.
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post #3 of 8 Old 06-17-2019, 04:30 PM
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Drill and tap hole one size up bigger . Use another bolt one size bigger

2013 KQ 500axi Camo eps and recoil starter installed
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post #4 of 8 Old 06-17-2019, 05:37 PM
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If the whole is stripped you could get a thread insert like a helicoil or other's. If done correctly they are a good repair option. I've had good luck with the thread inserts I've used.

Basically drill it out and tap it with correct size tap. It's usually supplied with the kit. Thread in the insert with threadlock and trim it if needed. Wire type inserts like helicoils use special taps. You have to use the correct type or it wont work.

If done this way you can keep the stock size bolt stud or plug.

Last edited by 440Tim; 06-17-2019 at 05:41 PM.
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post #5 of 8 Old 06-18-2019, 01:00 PM Thread Starter
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Thanks all. Was speaking with an acquaintance who's a mechanic last night. He suggested the Helicoil, with which i was unfamiliar. I'll let it go for now keeping an eye out for leaks, then give that a shot if they make the helicoils in that size next time I change the fluids. That's a bit of a relief hearing a potential solution that won't cost hundreds.

Cheers Lads!
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post #6 of 8 Old 06-18-2019, 03:53 PM
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They make helicoils for most standard and metric threads. Unless it is some weird thread pitch nobody else uses you should be ok.

You just need to know the size and thread pitch. So you can get the correct insert and tap.
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post #7 of 8 Old 06-19-2019, 06:12 AM Thread Starter
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Thanks 440Tim.

I have a feeling it's the housing as opposed to the bolt, so I can take that in with me to make sure I get the right thread pitch when buying the helicoil.

Still amazed at how soft that housing is. Didn't take much of a pull on the ratchet till it went mushy.

No mention of torque setting in the owners manual. I guess I should stop being such a cheap SOB and get myself a shop manual. Will no doubt come in handy now that the bike's a few years old and over 4300 km on it.

Can't complain one bit though - first issue of any kind... so far.
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post #8 of 8 Old 06-19-2019, 09:41 PM
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Some bolts and plugs don't take much torque at all.

Just keep in mind its a drain bolt. If you use a thread insert don't put it in too deep or it will stick up into the housing. If it's sticking up into the housing it probably won't drain completely and could possibly interfere whith moving parts. You can always trim off any exess sticking out on the outside.
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