On just about every XS 650 sump plug I have seen the hex has taken a beating . Lately I have been fitting other sump plugs to them. On the latest two I bought sump plugs, before that I just used a bolt and drilled the end to take a 6mm cylindrical magnet.
Here is the process in pictures.
First cut off most of the old hex, I used a cut off wheel in a grinder.
Machine the hex off and drill and tap a hole to suit your new plug
Clean the remains of the old magnet out
Not shown drill two blind holes in the hex face to suit a face spanner
Replate the now bare metal
Install the new smaller plug.
When I install these modified sump plugs I use a copper washer on the old body and locktite on the thread. Tighten it up using a face spanner.
I did try making these out of Ally (like the ones MMM sells) to shed some weight but found the thread gauled before I could get it in far enough. I suppose I could have cut a thread with more tolerance but decided to go this way.
Here is the process in pictures.
First cut off most of the old hex, I used a cut off wheel in a grinder.
Machine the hex off and drill and tap a hole to suit your new plug
Clean the remains of the old magnet out
Not shown drill two blind holes in the hex face to suit a face spanner
Replate the now bare metal
Install the new smaller plug.
When I install these modified sump plugs I use a copper washer on the old body and locktite on the thread. Tighten it up using a face spanner.
I did try making these out of Ally (like the ones MMM sells) to shed some weight but found the thread gauled before I could get it in far enough. I suppose I could have cut a thread with more tolerance but decided to go this way.
