I had to cut a slot in the old torx style mag plug to remove it, and I went too deep and nicked the crank case. Now, with the new plug, it is leaking. What would be the best way to stop the leak?

  • Re: Mag plug leaking

    by » 5 weeks ago


    Loctite 592 Thread Sealant should be easily available.

    My favorite for anything that leaks is "Permatex Aviation Form-A-Gasket #3".
    Works great on Fuel lines, Oil Hoses, Coolant hoses, and of course, Bolt Threads.
    - - -

    Edit:
    This is the first time I have ever heard of needing to Cut a Flat slot in a TORX Bolt.
    Are you sure this wasn't a HEX Bolt???

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    whertzel1@yahoo.com
    Clicking the "Thank You" is appreciated by all.

  • Re: Mag plug leaking

    by » 5 weeks ago


    Yes, it is a T40 and such a common issue that there is a video about it on this site, and Rotax came out with a different part. What really peeved me is that I took it to a Rotax-Certified guy, and he went and cammed it out worse with a hex key!

    Thank you said by: Bill Hertzel

  • Re: Mag plug leaking

    by » 5 weeks ago


    Thanks, Nate,
    I was not aware of that problem.
    I have a newer engine that came with the New 16mm Bolt Head plug.
    I will advise everyone to always use a 6-Point Socket for maximum effect.
    12-Point sockets are more prone to stripping the head.

    Putting a Hex Wrench in a Torx Bolt is a recipe for disaster.

    For those looking for the video...
    https://www.rotax-owner.com/en/all-videos/expanded-video-instructions/295-magplug

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    whertzel1@yahoo.com
    Clicking the "Thank You" is appreciated by all.

    Thank you said by: RotaxOwner Admin

  • Re: Mag plug leaking

    by » 5 weeks ago


    I generally go for 6-point sockets anyway (don't actually own any 12-points), but I don't think anyone will have any problems with the new bolt head style--It's just so much bigger than the T40.

  • Re: Mag plug leaking

    by » 5 weeks ago


    I have never seen a T40 Magnetic Bolt.
    Out of curiosity, was it an Aluminum bolt?
    If so, that was the real problem.

    I have used a cheater bar on Steel Torx Bolts and have never stripped one.
    I have twisted the Torx bit like a helix and it still held.

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    whertzel1@yahoo.com
    Clicking the "Thank You" is appreciated by all.

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