Gallery plug leak - Triumph Forum: Triumph Rat Motorcycle Forums
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post #1 of 24 (permalink) Old 04-20-2016, 02:03 PM Thread Starter
Grand Prix 500
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Gallery plug leak

I need to stop cleaning my bike. Last time, I knocked off the rubber cover on the oil cooler wiring because it had dried up and cracked.

Cleaning her up last night, I noticed oily spots on the front of the engine below the starter. Quick research here points to the gallery plugs. I can see one, centered in the engine over the starter. Is there another plug?

Thanks!
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post #2 of 24 (permalink) Old 04-20-2016, 02:42 PM
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There are four in all. Two of them are inside the engine cases and invisible, and another two are below the starter motor. We've had a thread about them a few days ago, see post 5 which also has a link to a more thorough description by me and lots of useful advice from other members:

https://www.triumphrat.net/air-cooled...last-week.html

Last edited by Forchetto; 04-20-2016 at 02:47 PM.
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post #3 of 24 (permalink) Old 04-20-2016, 05:24 PM Thread Starter
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Thank you very much! Looks like an easy project. Not quite like splitting my BMW in two to fix a rear main seal leak.
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post #4 of 24 (permalink) Old 04-21-2016, 09:27 AM
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Originally Posted by Gone in 60 View Post
Thank you very much! Looks like an easy project. Not quite like splitting my BMW in two to fix a rear main seal leak.
It really is pretty easy and once you have done it you will be glad you took the time to fix them. I am real fussy about leaks. As posted go by Forchetto - read the postings a few days ago and you will have the job covered with no problems.

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post #5 of 24 (permalink) Old 04-21-2016, 04:16 PM
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The fix is easy. The access is difficult.

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2005 Bonneville Blue 790cc, AI removed, Staintunes RC, no snorkel, inlet enlarged, 118/40/NBZT needles/1 shim/3 turns, Ikon 7610s, Ricor Intiminators, Barnett green clutch springs, Michelin Pilot Activs, D9 gauge panel, tachometer.
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post #6 of 24 (permalink) Old 04-21-2016, 04:58 PM Thread Starter
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Question, I couldn't tell from the previous posts. There's the one countersunk plug visible above the starter, with two button-head hex screws pointing upward on either side of it. Are those plugs as well? They don't appear to be leaking. Are the other plugs visible once the starter is out of the way?

Almost looks like the big one in the middle could be accessed with a large Allen wrench without removing anything, but with little leverage space.
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post #7 of 24 (permalink) Old 04-22-2016, 01:44 PM Thread Starter
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Well, I answered my own question once the starter was loose, and I saw the second plug. Challenging to get to, but with extensions and u-joints was able to get to them over and under the starter. Wrapped them with Teflon tape and reinstalled.

Interesting that taking a closer look, oil looked like it was sweating out along the joint between the oil pan and block, and those screws were a bit on the loose side. Snugged them up as well.

I'll pick up some oil over the weekend, fill it up and keep my fingers crossed.

Thanks for your help, guys!
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post #8 of 24 (permalink) Old 04-22-2016, 01:58 PM
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Interesting that taking a closer look, oil looked like it was sweating out along the joint between the oil pan and block, and those screws were a bit on the loose side. Snugged them up as well.
Funny how often we get loose or even missing screws from the sump plate, I wouldn't have thought that particular area was prone to any more vibration or stress as anywhere else in the engine and there are 11 bolts altogether in there. Worth checking at every oil/filter change, I think. Torque is 12Nm (8.8 Ft/lbs).

Last thread with a missing bolt in there just a week ago:

https://www.triumphrat.net/air-cooled...sump-bolt.html
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post #9 of 24 (permalink) Old 04-22-2016, 03:54 PM
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Funny how often we get loose or even missing screws from the sump plate, I wouldn't have thought that particular area was prone to any more vibration or stress as anywhere else in the engine and there are 11 bolts altogether in there. Worth checking at every oil/filter change, I think. Torque is 12Nm (8.8 Ft/lbs).

Last thread with a missing bolt in there just a week ago:

https://www.triumphrat.net/air-cooled...sump-bolt.html
Perhaps from the gasket compressing over time? I did my clutch springs in the fall and the clutch cover bolts had almost no torque when I removed them. I retorqued all the cover bolts, never thought about checking the sump though. I had to do my gallery plugs last fall as well.
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post #10 of 24 (permalink) Old 04-22-2016, 04:08 PM
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Perhaps from the gasket compressing over time?
Good point, that's likely the reason. Car manufacturers are abandoning gaskets in lots of engine joints nowadays. Just looking under a new car you'll see bright orange silicone gasket paste oozing out of lots of joints.

There's another advantage to the makers in that the gasket compound can be applied by robots, no stockage or lining up of complex solid gaskets or anything.
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