It’s Hard to Change the Oil When Installing a Collection Tube, so Add a Drain Bolt!

OI01b.jpg How to

For a four-stroke engine, it is important to change the oil, and for the bodywork, it is important to adjust the drive chain tension. Even if you understand the importance of such maintenance, there are times when you cannot change the oil or adjust the drive chain, which should be easy to do, depending on the customization. Customization requires a certain degree of preparedness. It is normal to be able to change the oil and adjust the chain as usual. However, when you try to customize your motorcycle, you may find yourself at. In this section, I will report on some of the cases that challenged such a high barrier.

Doesn't it need a main stand because it's an assembly tube?

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Not only does the motorcycle feel great to ride, but it also needs to be smooth and easy to take care of. I modified the stock main stand for the GSX750E, which has a narrower exhaust pipe and a deeper bank angle, to allow me to install a main stand with a 4-in-1 exhaust system.

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The angle of the pipe was changed and welded, and the plate reinforcement was welded in the part that did not interfere with the exhaust system, and the layout was examined so that the tail pipe of 4-in-1 and the main stand would not interfere in the whole area (during operation). After we got a good idea of what we were going to do, we moved on to the main welding.

Even 4-in-1's can now change their oil!

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When you use the side stand and lean the vehicle to the left, find a position where the engine oil will drain smoothly. If there is a drain plug (drain bolt) in that position, the engine oil can be drained smoothly. So I bought a used oil pan as a spare. I made the seat of the drain bolt by cutting with a lathe.

Additional drain positions machined as envisaged

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Requested Inoue Boring to do the machining. I made it so that the drain plug seat can be installed in the marked position. This position will allow the engine oil to drain smoothly when using the side stand.

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The position of the additional drain was determined by machining, but when welding the seat of the drain bolt to it, it was found that the tip of the argon welding torch was difficult to enter. So I used a rheuter to cut a part of the cooling fin to avoid interference.

Argon welding is done by experienced professionals.

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Club 1 specializes in building special motorcycles and racing machines. To 2FK, requested to weld the drain plug seat. Since the oil pan is made thinly, he told me that it will definitely be distorted after welding. If it happens, I'll think about it again.

 

Weld complete in one batch, but

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The cooling fins next to the drain seat were machined to allow the welding torch to enter smoothly and draw a beautiful bead. The inside of the oil pan was modified to allow the engine oil to flow out smoothly after welding from the outside. A through hole was added in the middle of the thread of the additional drain, and it was imagined that the engine oil flowed out smoothly. However, when the oil pan after welding was put on the surface plate, it was found that the gasket surface was distorted, and it did not touch perfectly. At that time, when I hit it with a large rubber hammer in the opposite direction of the distortion, the distortion was almost corrected, and the gasket surface fit perfectly by sliding it together on the surface plate.

Even with a 4-in-1 assembly tube, the drain is in this position

Installed a new oil pan which has been modified. I have ride the motorcycle several times after the modification, and there is no oil seepage at all. If you look at the position of the standard drain plug, you can understand why the oil cannot be changed. The additional drain plug is for the Honda horizontal type with 17mm bolt head.

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POINT.
 
  • Point 1. Customization is not all about bolt-on parts, it can be created by the owner.
  • Point 2・ After explaining and understanding the direction of customization, it is best to ask a professional to do the actual work.
  • Point 3 - The main stand can be used even with collective pipes, and oil changes can be easily performed even with collective pipes.

 

Just by changing the exhaust system, you can change the impression of driving. However, the changes caused by the installation of the exhaust system may occur in other situations as well. Depending on the product, the exhaust system and drain bolts may not be in the correct position, and with the exhaust system installed, the drain plug may not be able to be removed, making it impossible to change the oil. There are also many cases where the main stand has to be removed due to interference between the exhaust system and the main stand. When the main stand is used, the drive chain tension can be adjusted quickly. However, if only the side stand is used, the workability often becomes much worse.

Not only the Suzuki GS1000, but also the Kawasaki Z1 and KZ1000 series often require the main stand to be removed to install the assembly tube. I'm sure there are many Sunday mechanics who have had this experience in the past.

If we install the collective exhaust system on the GS1000, we will have to face this inconvenient "double punch". Then, I thought to leave the normal exhaust system on, but the feeling of the collective exhaust system has a different taste and is really attractive. The exhaust system can not be installed without removing the main stand, and the maintenance of the drive chain becomes worse by removing the main stand. I wondered if it was possible to enjoy the motorcycles without sacrificing either, and I thought that I might be able to counteract this by further customizing it to my own specifications. The customization challenge was the installation of a modified main stand and the addition of a drain bolt with a modified oil pan.

I've had past experience modifying other models, but being able to use the main stand with a collective exhaust system is so much more convenient. Also, the modified oil pan makes it possible to change the engine oil without removing or loosening the exhaust system. This customization is the embodiment of these ideals. This was a concrete example of both improved maintainability and ideal driving feel.

When I modified the oil pan, I welded on an additional drain seat to change the location of the drain bolt. This caused the gasket seat to distort and warp. Club 1 who asked me to weld it. According to Mr. Ohira, the representative of 2FK, "The warped seat surface can be returned by hammering. This time, we hit a part of the oil pan with a rubber hammer while the heat of welding remains. Of course, this correction by hammering is a know-how that can only be done with experience. To my surprise, the distortion disappeared after the blow by the hammer, and the gasket surface did not shake on the surface plate. To make sure, before installation, the surface was easily adjusted by using the surface plate, but the oil pan could be installed perfectly, and after that, there was no oil leakage or oil seepage.

 

Cooperation by:
iB Inoue Boring (machining)
Club 1.2FK (aluminum welding)

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