I988 Sportster 883. I just recently bought it. When I removed the primary drain plug, it looked like there was already a helicoil in it but the helicoil was coming out. I tried to clip off the end that was sticking out but it seems impossible. The drain plug is leaking a small amount.

I would like to remove the current helicoil and replace it with a new one. I have read that time-sert is a better option but I prefer to stay with helicoil because the threads are already tapped. My questions are:

1. Can anyone confirm that the size I need is 1/2 x 20?
2. How do i remove the tang? Will I have to take off the primary cover to recover the tang after it has broken off?

Thanks for any help.

 

If you really do have a helicoil and it is coming out, the threads are done for. Putting in another is unlikely to solve the problem. The cover is not very robust and I can't see any alternative but to remove the cover to repair it. Frankly I would find a local indy to see what he recommends. An insert of some sort is one way, an alternative is to weld up the hole and start again.

AFAIK the original drain plug is tapered, while thread inserts are normally parallel threads. That is probably why your helicoil has given problems - it is not suitable.