XJ650 - Copper sealing washer

I'm looking for a replacement, (not OEM) copper sealing washer for my 1980 4K0 UK spec. XJ650. It's for the middle gear drain plug.

The OEM part is described as a washer plate with the part no. 90201-08087.

See ebay link, LOT OF 2 Yamaha OEM Washer Plate 90201-08087 | eBay

Does anyone know or can measure the ID & OD of this washer in order that a may source a replacement.

Otherwise, it'll have to wait until next time I do an oil & filter change.

 

If anyone in the UK is looking for a supply of washers, Wemoto have a good selection, https://www.wemoto.com/components/fastenersnutsboltsandscrews/washer

Wemoto do the sump plug washer, https://www.wemoto.com/bikes/yamaha/xj_650_4k0/80/picture/sump_plug_-_drain_ally_washer have ordered three.
The final drive bevel box drain & fill plugs are the same M14 size. Any orders less than £5.00 are free P&P.

 

Clean and anneal the one you have, then reuse it.

 

Thank you, that's one option, a new replacement would be good.

This is the bolt which the washer has to fit, 90105-08729 NOS Yamaha Washer Based Bolt XT500 SR500 XJ700 TZ125 XJ650 Y125c | eBay does it help to size the washer.

 

FWIW, it's not really necessary to ever remove that drain plug. There is so little oil in there (less than a cup), and it all ends up being mixed with the new oil anyway.

 

The Yamaha owner's manual, Haynes manual & this service manual, https://www.xjcd.org/book/export/html/35 all recommend removing the middle gear drain plug. I agree that there is very little oil drains out.

Until a friend made me a tool to access the plug between the frame tube and 4-2 exhaust collector box, I used to remove the complete exhaust system, as per this video of a 750 Maxim,



The Haynes manual suggests using new sealing washers too.

 

Look, it's a really nice, comfortable feeling to be able to remove that last little bit of oil, it makes you feel like you went that "extra mile" to do the job 100%, but it's really not worth the risk......the risk being shearing off that 30+ year old bolt ("drain plug") that was a somewhat low-grade steel to begin with. And once it shears off, you've got a Headache Extrodinaire to deal with, and unless you're a contortionist (with mini, contortionist-type tools) you ain't getting that now sheared-off remnant out w/o pulling the engine......of course, that's not an end-of-the-world task, and it will give you an opportunity to clean and perhaps detail your engine and frame a bit, but it's better to do those things optionally, as part of a plan, rather than being forced to do it before you can ride again.......

 

The XJ650 has been owned by myself from new, it's now 40 years old and has done 52,000 miles. During that time & mileage, it's had 38 engine oil & filter changes, all done by myself. On every occasion, the middle gear drain plug has been removed without any problems. When the plug is replaced it certainly isn't tightened to the torque setting of 24 Nm or 17.5 ft lb as per the Owner's & Haynes manuals or Yamaha UK specs. The tool I had made is basically a 10mm socket with an allen key fitted to it. No more than thumb pressure is applied at the end of the fairly short length of allen key.

Meanwhile, having searched this forum & spoken to Yamaha UK, the drain plug seems to be M8, requiring something like an 8mm x 14mm Cu washer. I don't think the plug is 8mm dia. as the washer is a sloppy fit and needs to be held in place to keep it concentric when nipping up the plug.

Wemoto do this M8 x 14mm Cu washer, although it's only 1mm thickness, https://www.wemoto.com/parts/picture/hl-910021_50 Most sealing washers seem to be 1.5mm, hopefully, that won't be a problem.

 

Nice one.

 

If the material quality of the OEM drain plug is questionable, could always replace it with one in stainless steel, https://a2stainless.co.uk/product/m8-x-16-flange-socket-button-screw/

 

Stainless LOVES aluminum. So much so that they tend to exchange electrons and eventually become a single part.

 

Use anti-seize on the threads of a ss bolt, and use a copper washer under the head to insulate the stainless from the aluminum part.

Perhaps this is why the OEM bolt has a Cu washer, rather than Al.

 

Ah, the old electron-exchange dilemma....a real pain in the tailpipe. Thank goodness electrons have other, more useful features.

Some people say they even powers the sun:

 

This is one way of accessing a sheared off drain plug.

 

Yeah, just pick it up and turn over!

 

In the UK, GWR Fasteners will sell any quantity of sealing washers, no minimum order, just pick up the phone and give them a call, https://www.gwr-fasteners.co.uk/sealing-washers-983-c.asp

 

Copper was used because it expands when heated and nowadays aluminium is much cheaper.
Ofcourse there can be/are metallurgic issues but no so quick, especcially not with the oildrainbolts.

 

Where the OEM spec. was Cu, would you be happy to replace it with the more cost effective Al.

 

I already have..