QuestionHi,
I recently purchased a Kawasaki ninja 500R. I was trying to do my own first oil change and in a moment of complete stupidity, I tightened my Main Gallery Plug instead of loosening the oil plug at the bottom of the sump. When I did this, I broke the main gallery plug. I tried to do this myself because I'm a college student and cannot afford the $140.00 that my dealer wants to change my oil. I have purchased a new main gallery plug (part #92066-1205), and a fairly decent torque wrench. I need to know how to install the new gallery plug, and if there is a way to verify that my installation was done correctly. Thank you very much for any assistance or advice that you can offer.
AnswerHi Chris,
The best advice that I can offer is for you to obtain a copy of the service manual.
The service manual has illustrated procedures for all maintenance and repairs, with the exception of certain machining work.
The service manual will pay for itself with the first work you perform. It's the best ivestment you'll make into your new Ninja.
Get the Kawasaki brand manual. Avoid less expensive Clymer and Haynes brands. You get what you pay for.
About the repair:
Before you install the new Gallery Plug, are the engine case threads in good condition? If not, repair them or have them repaired. If you perform the repairs, use a Heli-coil, Time-sert, or other thread repair kits.
If threads are not damaged, install the new Gallery Plug and torque to service manual specs (sorry- I don't have the manual.) The copper ring with the plug is a gasket, not a washer.
View microfiche parts at:
www.buykawasaki.com
View microfiche parts, compare parts prices, and order manuals at:
www.bikebandit.com
You may also find manuals at eBay, Barnes & Nobles, and other on-line resources.
Always include your email address as requested in my instructions. I return tech files to you via your email addy.
Respectfully,
Mark Shively
