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[ultra13]

For all you fellas that change your own fluids...Have you ever had a transmission or oil drain plug o-ring not play nice? When tightening the plug the rubber seal wants to squeeze out on 1 side or the other of the plug when just about properly torqued. I tried multiple times to install it with no luck.    Puzzled..

[motor1]

When installing a new O-ring you cannot allow it to twist (not saying that is what you did) but if it is distorted or twisted in anyway it will stretch and squeeze out when tightened. It happened to me a couple of times I wound up replacing a new O-ring with another new O-ring; problem resolved.

[Smoketown]

Once an O-ring starts misbehaving, it needs to be replaced.

Sometimes if the O-ring is close (slightly oversize) and not the correct size, the same thing will happen.

Although, even a slightly smaller O-ring will work ... Providing that there is some "squish" when tightened.

Cheers,
Smoketown

[dayne66]

This is what I found when doing the 1500km oil change after an ESP rebuild.

I checked the mating surfaces for any burrs ........nope....smooth.

I put on a new o-ring with a film of fresh oil... WITHOUT pipe dope......tightened to 20 ft-lbs......and loosened......7 times with ZERO damage or distortion to the o-ring.

[muddypaws]

I put a little lube on the "O" ring and also teflon tape on the thread. Works great every time.

[grc]

    Agree on the light film of oil on the o-ring before installing the oil plug.  You don't want the ring to grab, stretch, and tear.

Jerry

[iski]

I put a little lube on the "O" ring and also teflon tape on the thread. Works great every time.

x3, depending on fit will skip the tape sometimes.

[ultra13]

Tried a different o-ring but still had the same problem. Ended up just putting a lot of Teflon tape on it just to go on a ride that day as a temp. fix. Not sure how long that would last if I just left that on. I have more o-rings I will try it again. Thanks all.....

[dayne66]

Is there a burr on one of the mating surfaces?

[grc]

It's quite possible the o-rings are oversized or the wrong material, or just old.  Are you using o-rings from the Harley dealership, or something else?

Jerry

[ultra13]

Checked the mating surface and seemed good. I am using the HD O-rings. They seem to be a good tight fit around the plug.

[J.D.]

Never use teflon tape anywhere in an engine, especially oil drain plugs.  Reason is, if a chunk of that tape gets through the oil pump it can easily block a small internal oil passage.  If sealant is needed, use the teflon paste.

O-rings only get so many uses.  Check for burrs on the metal and smooth out if needed.  O-rings are well under a buck, just replace it.

[johnmowcop]

Tried a different o-ring but still had the same problem. Ended up just putting a lot of Teflon tape on it just to go on a ride that day as a temp. fix. Not sure how long that would last if I just left that on. I have more o-rings I will try it again. Thanks all.....

Teflon tape is generally used on taper threads on pipe fittings (instead of the old Stag paste). I don't think the oil plug is a taper thread. If its a parallel thread it will have a flat face for sealing the application, using O-ring, Dowty washer or fibre washer. Teflon tape is PTFE, PTFE has no elastic memory so once deformed or put under mechanical pressure it will "flow". keep a check on the plug to make sure it does not start to weep. Mind you you will see a drip on the floor if it does.
JohnT

[Smoketown]

O-rings can be irritating ... Has anyone ever tried a nylon washer like on an automobile oil pan?

Cheers,
Smoketown

[ultra13]

Here is the update on the o-ring malfunction....I discovered that the bolt was not going in straight. Don't know much about the history of this bike but it appears that at some time during the fluid change the bolt was cross treaded, which explains why the seal was pushing out the back.  So after talking to a local bike mechanic, that told me he has seen a few of these before, I re-tapped the first couple of threads in the trans pan and it worked! The bolt straightened right up. I put some grease on the tap to catch any shavings. The other alternative was to drop the pan and install a helicoil. That didn't sound like a fun job.
I do like that nylon washer idea....Thanks all..