Went to change my oil on my 95 Ultra and when I took out the drain plug most of the threads came out as well.
What's the best way to repair a stripped oil drain plug on this?

 

Quick fix is an oversized drain pan plug. They come with a piggyback plug of a smaller dimension. Most GOOD auto parts stores sell them. I have used them with no problem but I changed out the gasket for a banjo type. This is not the right way to fix the problem, just one that will work.

 

My plug has pulled some threads too but there's enough that it still holds. I've been very carefull not to overtighten it ever since. So far it's been holding. I suppose eventually I'll drill and tap it for a larger plug...maybe when I pull it apart for something down the road. Until then...I'll tighten it just enough and watch for oil spots.

 

I have tapped & heli-coiled a couple with good success..
Red Loc-Tite on coil, once done you have threads that are steel, & stronger then stock.
Plus you still use the oem magnetic drain plug..

 

Did you do this with it on the bike?

 

"Did you do this with it on the bike?"

Yes, I put grease on the tap to hold the debris from tapping. Lil at a time..
In a few threads & back out & clean off tap..& repeat.

When done, you can bend a Q-tip on a 90* to rub around the hole in the pan, to be sure all is clean...

Works good..

 

Right on. How about holding the drill and the tap square to the pan? Did you make a jig to pilot them?

 

In stripped out aluminum, you can usually just use a good sharp drillbit by hand. Mostly, all you're doing is removing any remaining threads. Then the heli-coil tap starts in that hole and you're OK. Be sure to red locktite the heli-coil in that application, or use a timesert, which google ads is showing a banner on right now. You don't need a jig, just eyeball straight and go.

If you're not comfortable doing things like that, it may be best to take it to a professional.

 

You can buy an expansion plug that will serve the purpose with no mod to the existing messed up threads. Any good auto parts store should carry them. I've seen them as small as 7/16" on the narrow end. They consist of a rubber or rubber-like wine bottle cork shaped stopper with a hole through the center, a washer that is a little smaller than the small end, a scre that goes through the smaller washer and then through the stopper and a larger washer with a wingnut. If you are concerned about it coming loose, replace the wingnut with a pair of nuts so you can use the "jam-nut" method to lock it in place.
The heli coil method is a better option for a permanent fix.

 

+1 on Dr. Hess answer.. That'll do it.. Works for me.



mopardave-

with Ur rubber fix ya lose the magnetic plug, I like to see my magnetic plugs & know if any big particles of metal are starting to appear..& (hopefully not)