Auto parts store , you'll find oversize self tapping plugs in a number of sizes just be careful and thread it in straight . Common problem fixed more than a few over the years that way .

 

1. Get a slightly larger drain plug
2. coat the correct size tap with grease to capture metal filings
3. tap out hole
4. install new plug
5. done
Really no need for any drilling if you go just a size up on the hole maybe by using a metric plug. I did this exact same thing on the oil drain on my last bike. Super easy and cost next to nothing.

 

agree on the oversize plug or heli-coil. some heli-coil kits come with necessary drill and tap and insert tool. the complete kits usually run about 45-50 bucks.

which ever way you go, don't forget to clean and metal shavings from the primary.. don't waste good oil, just pour used oil in and and maybe a shot or two of brake clean..

 

yep sounds like the dealers really trying to drill you,you need to ask them if that order comes with a economy size jar of vasoline

 

or my favorite.. are you going to kiss me after that ? cuz you sure are screwing me.

 

Going to dealers today. Will firmly ask why not just "tap" it.
I dont know what they will say, but I suspect it may be something like this:...' your bike is under warranty. this repair is not. to keep it under warranty we need new inner primary cover. tap is not warranty.
My warranty expires in October.

 

Dealer won't got that way man they will only replace damaged stuff with oem new or oem used parts . They are not mechanics that will repair a problem they are part changers period . If they won't warranty it , find a local Indy shop or check these out I use them all the time to fix primary's the owners have heavy handed .

http://www.cgenterprises.com/drain_p...ize_repair.htm

 

Twisted has the right supplier. And just so you know, it's not the inner primary it's the outer primary cover. The inner is sometimes replaced with a chrome one for looks but the outer is already chrome on your fatboy. That big round thing on the primary cover is usually called a derby cover. The drain plug is just under that on the outer primary cover.

 

1. Find a buddy with a decent equipped garage
2. Bring along beer
3. Show him the hole and he'll be able to tap it and insert a new plug. Takes longer to find the right tap and bolt than to actually do it.
4. Spend the rest of the afternoon finishing the beer and congratulating yourselves on a job well done.

 

Oh yea, if you have a wife, tell her u guys worked hard and saved $1,000. She'll let the drinking pass, lol