1100GS Gearbox oil drain plug

Discussion in 'GS Boxers' started by Three Dawg, Nov 18, 2013.

  1. Three Dawg

    Three Dawg Into Africa

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    Just changing the fluids in my 97 1100GS and didn't notice a washer coming out with the gearbox drain plug. Is the one I have the later revised 'washerless' one, and if so, am I right in thinking that the torque setting for this type is higher (circa 30Nm rather than 23?) than the ones with a crush washer? The Haynes manual doesn't seem to mention a washerless type.

    [​IMG]

    It's been suggested that the washer may still be attached to the gearbox, but if it is, I can't shift it:

    [​IMG]
    #1
  2. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Looks like the washerless type. I am not aware of a different torque value for it.

    Jim :brow
    #2
  3. Three Dawg

    Three Dawg Into Africa

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    Cheers Jim.
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  4. Jim Moore

    Jim Moore Long timer

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    Can I tell you my theory on that? My theory on that is this. They're all supposed to be 32 nm. 23 nm is a misprint. They transposed the numbers in several places in various manuals. 23 nm won't crush the washer. I've had drain plugs leak after being tightened to 23. I use 32 nm for all of them.
    #4
  5. Three Dawg

    Three Dawg Into Africa

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    Just done up the drive housing fill and drain bolts to 23Nm with lightly oiled threads and they felt pretty tight to me- 32 seems quite a lot on a relatively short thread.
    #5
  6. AntonLargiader

    AntonLargiader Long timer

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    JimB: that plug takes a crush washer. You can see the taper and the absence of a sealing lip.

    JimM: Thanks for at least saying that it's just your theory. The washerless plugs really do have a higher torque. It's described in a bulletin (listed there as 30 Nm actually).
    #6
  7. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Anton, do you have a photo of that plug with a crush washer on it?

    Jim :brow
    #7
  8. AntonLargiader

    AntonLargiader Long timer

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    This shows the two plugs types. One has a taper to center the crush washer, and the other doesn't but has extra grooves on the face to seal against the transmission (and gets the higher torque). There are several other plug configurations but the main difference is this:

    [​IMG]

    The OP's drain plug has a step in it which may have mashed the crush washer outward and jammed it into the machined bore in the trans case. It's really hard to tell sometimes if there is a washer stuck in there.
    #8
  9. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Thanks!

    I am pretty sure there is no crush washer stuck in here, the picture is very clear:

    But, it is easy enough to figure it out.

    Jim :brow
    #9
  10. Three Dawg

    Three Dawg Into Africa

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    Sheesh, how many types of drain plug does one bike need?

    Unless there is a washer that obviously fits that taper arriving with my other bits and pieces today I think I'll just bung it back in at 23 Nm and keep an eye on it.
    #10
  11. Dan Cãta

    Dan Cãta Long timer

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    I suggest you change the plug to the one on the L/H side, it is a better design than the one that uses a allen key. Had to replace the gearbox oil on a friend's bike recently and the PO screwed the bolt so hard in, that I broke the 6 mm bit in the plug :|

    This would not have happened if he would have used the torque wrench and the outer hex head plug...

    Dan.
    #11
  12. AntonLargiader

    AntonLargiader Long timer

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    He already has that one; you can see it in the first post. But you're right, the 6mm Allen version is problematic that way. I've dealt with a few tough one, too.
    #12
  13. Basic_Gerd

    Basic_Gerd Gerd

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    [​IMG]

    This one was mounted without washer too. I would never omit the washer, because it protects against that seizing. Way too dangerous for the housing.

    Without that grinding compound trick that screw would not have come out.
    #13
  14. Three Dawg

    Three Dawg Into Africa

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    Put washer on plug, put plug in hole, tightened to 23Nm. Should be OK. Thanks for all replies.
    #14
  15. AntonLargiader

    AntonLargiader Long timer

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    If there's no centering taper, you shouldn't use the washer because it could get far enough off-center that it leaks. Better to change to a washer-type plug.
    #15
  16. Anorak

    Anorak Woolf Barnato

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    From your photo it sure looks like there is a distorted washer stuck in there.
    #16