change my oil pan on my 04 zx6r

jetblack3s · 11-18-2007, 09:12 PM

i was doing my oil change on my zx6r, i guess i tighten the drain plug too much the oil pan cracked. lol, now i need a new one, how hard is it to change the oil pan? do i need new bolts and gasket when i get a new or used oil pan? and where can i get one for cheap?

Veefer97 · 11-19-2007, 12:25 PM

You can fix the oil pan for $30
OK so you messed up. In your hurry to get the oil changed you applied too much torque and that sickening feeling of the plug turning without tightening is keeping you up at night. Have no fear, there is an easy fix. Easy if you have some basic mechanical knowhow. Of course you striped the threads so the basics are in question. Never mind, just follow the steps

1 Go to any decent auto parts store and buy the Thread Repair System ($30).
Hint: take the plug with you on the off chance that they carry multiple sizes

2 I prefer to lay the bike on its side as it is easier to work on. You do what you want.
3 Place grease on the tapping tool so that it may catch any aluminum chips.
4 Using a socket and ratchet thread the tool into the stripped hole until the tool goes in to the top of the second set of threads
5 Remove taping tool. See all of the chips on the tool. Aren't you glad that you put grease on the tool.
6 Clean out the hole of any chips. I used a dentists pick and some paper towels to drag any chips out. That would be beyond the hole. You may also want to flush the pan out with a cheap quart of oil or for you anal types just take the oil pan off and don't send me any nasty replies about how you did it better.
7 Clean any oil off the threads using the chemical of your choice. I also use a Locttite primer, nice but not necessary.
8 Select the proper lenght of insert by measuring thread depth.
9 Thread the insert on the first tapped portion of the tapping tool. The knurled portion of the insert should be the last part to go into hole. Look at the pictures on the box or the next photo
10 Apply locktite to insert
11 Thread the insert into the hole until it bottoms out with no threads of the insert outside the drain pan hole.
12 Place swager into the insert and strike with hammer to expand the knurled portion of insert
13 Put the drain plug back, you are done. Next time be more careful with aluminum threads

jetblack3s · 11-19-2007, 06:29 PM

i am not sure if you know what i meant, the oil pan cracked? not the bolt..

Veefer97 · 11-19-2007, 08:04 PM

Sorry, did not read post as close as I should have. You need a new or good pan.

jetblack3s · 11-20-2007, 12:54 AM

is the job difficult? i just need to put the bike on stand, and take out all the bolts holding the oil pan, then clean the edge, then install new pan and gasket right?

Fred · 11-20-2007, 01:15 AM

its not very hard at all to be honest. Look on ebay for a pan. Order a gasket and your all set. You can always go to Ron Ayers and order a new pan for a good price. Ron Ayers Motorsports - Motorcycle, ATV, Jet Ski and Generators Parts and Accessories

kevinwilly · 11-20-2007, 01:21 AM

What's it made out of?

If it's steel or aluminum you could take it someplace and have it welded. Then you could use the thread repair insert.

Most likely easier to just replace it, though.

And yeah- you'll need a gasket, some rtv for good measure- the red stuff works great for this, and a new oil pan.

Oh- and obviously new oil.

I can't remember exactly what you have to take out on the 636 to get the oil pan off... it's been a while since i worked on one. My GF has an 03 that i'll be riding this weekend. If you want, i can take a look and tell you exactly what you need to know. But honestly, i'm sure you can figure it out if you take your time.

Veefer97 · 11-20-2007, 07:26 AM

The exhaust system may have to come off. Sometimes the radiator needs to be loosened or removed as well in order to remove the exhaust. Not hard but time consuming. When you do get the new oil pan on and fill with oil, loosen the oil filter so that there is a slight gap between the oil filter gasket and engine case. As soon as the engine is started, oil will pour out of the gap. Shut engine off and secure oil filter. Kawasakis are prone to losing the oil pump prime and many people have toasted their engine due to it.

marko138 · 11-20-2007, 10:18 AM

Don't forget to get under the bike and scrape the old gasket material off of the crank case. If you don't you'll be doing this again...cuz that sucker will be leaking oil.

adamp961 · 11-20-2007, 12:16 PM

When you use the red rtv silicone, remember not to over due it. Lightly coat the gasket because if you over due it the extra will come out the sides and get into you oil system and maybe clog the oil pump or filter.

jetblack3s · 11-21-2007, 05:50 PM

yes, sir, thank you very much!