1986 Force 125 Lower end gear lube change

[mbhoag]

I am working on my 1986 Force 125 that I recently purchased, changed the water pump impeller, installed a new stator and Packs (stator and 1 pack were bad) and I have 2 things left to do...

1. I need to change the lower end gear lube, but I have been through every Allen wrench I own and cannot find the correct size to fit. Does anyone know what size of allen screw the drain plug is? I do not wish to strip it with the wrong size.

2. The upper carb completely drains all gas when the motor is tilted up. (the lower carb does not). I assume a small amount of gas leakage is normal, but I think what is coming out of the upper carb is excessive. Is there an adjustment or quick fix I can attempt before pulling the carb and doing a rebuild?

Thanks for your help!

Mark

 

[bentle]

Re: 1986 Force 125 Lower end gear lube change

Lower unit drain should be a flathead type screw.someone could have installed allen type but it should be flathead. Drain is located on very bottom of gear housing. Don't remove the next one up that sits deeper in housing. For the carb question it sounds like a float adjustment and you will need to pull carb to do the adjustment, and if you are going that far then go ahead and clean carbs. May as well do spark test and compression on each cylinder just to make sure all is well there to.

 

[Jiggz]

Re: 1986 Force 125 Lower end gear lube change

My lower end drain plug is an Allen head screw. I'll have to check it tomorrow to see what size of Allen wrench it takes.

 

[jerryjerry05]

Re: 1986 Force 125 Lower end gear lube change

Most Early Forces had an allen head screw.Later they went to a slotted screw.
It's an SAE/American If they won't fit it's been stripped.
Try a metric allen head.That not fit.
Then the only thing to do is.Drill and easy out.
Not ready to do that,then just start filling from the fill port untill the dirty oil comes out clean.
Or take it off and drain it by tipping it upside down.

 

[pnwboat]

Re: 1986 Force 125 Lower end gear lube change

If the allen head (standard or metric) doesn't get it, try a torx bit. I've had pretty good success with them. May have to tap it in with a hammer and it'll mess up the allen head screw, but the allen head screw is replaceable. It's pretty common for the drain plug to be a problem to get out. If neither method works, like Jerry said, drill it out. I've done it before, drilled and tapped it for an 1/8 X 27 pipe plug allen head screw.

 

[Jiggz]

Re: 1986 Force 125 Lower end gear lube change

I checked mine today and the perfect fit was a 5/32 allen wrench. On some motors, this part of the bullet gets dinged many times or get grounded to the point the allen head gets a little deformed. But with a little force it should fit in there. I've tried a trick before where I filed the allen wrench tip sides a little just to get started into the hole.