Stripped threads on oil plug (1980 KZ750)

I just got my bike out of storage after a nice long winter here in AB, Canada and went for a quick ride then got ready do the standard oil change. When I connected the socket to the plug I noticed that it was turning fine but the plug was not coming out. I can't tighten it or loosen it so it looks like the threads must be completely stripped. I'm not too mechanically inclined unfortunately but I did try to turn it with a vicegrip while pulling down but that didn't do anything. I couldn't even get it started at all to get a screwdriver in between to help it along or anything. If anyone has any suggestions of what I might be able to do to get this off it would be much appreciated. Thanks all.

I think your on the right track. A Good Pair of Real Vice Grips, and a pry bar while turning. You may have to pry on the Vice Grips first before you can get to the edge of the plug. Then hopefully your Auto Parts Store, should have a oversize plug. I would Tap for an oversize before using a Self Tapping plug. Or you could Time Sert or Heli-Coil back to stock and get a new plug thats correct.

Worst case, pull the pan off, and then repair the threads, or replace the pan with a good used one.

I had a similar problem a number of years back and like Motor Head said you are on the right track with the vise grips. Just make sure you are turning in the right direction.

Kawasaki.com, owner info, motorcycle etc etc says that oil drain plug is 12 x 15 and you should be able to get an oversize one off the shelf at Canadian Tire or an auto parts store. I got a temporary one like in the pic from Canadian Tire and while it worked I really didn't have confidence in it and it seemed I needed to check and tighten every few days.
Good luck.

JR wrote: I had a similar problem a number of years back and like Motor Head said you are on the right track with the vise grips. Just make sure you are turning in the right direction.

Kawasaki.com, owner info, motorcycle etc etc says that oil drain plug is 12 x 15 and you should be able to get an oversize one off the shelf at Canadian Tire or an auto parts store. I got a temporary one like in the pic from Canadian Tire and while it worked I really didn't have confidence in it and it seemed I needed to check and tighten every few days.
Good luck.

That would be in an Emergency Only, and would be to get somewhere for a repair, or home. Expecting it to leak some.

Motor Head wrote
"That would be in an Emergency Only, and would be to get somewhere for a repair, or home. Expecting it to leak some"

It kept me going until I got a replacement oil pan. The drain plug that was in there was already oversize

From Gadget's fixit page - Stripped Oil Plug? Not a Problem!

If the oil pan is stripped, you could replace it. There are plenty listed on ebbaayy. I would ask the sellers to verify that the drain plug & oil pan threads are good. Your bike has the same oil pan as all KZ650s & most KZ750-4s up to 1983.

So ended up having to get a guy to remove the exhaust and then take off the oil pan. My luck gets worse from there. In the bottom of the oil pan when he took it off he found a couple of pretty good size metal pieces and a plastic piece which he said was a piece of the cam tension belt I believe thats what he called it. It was a decent sized piece at least an inch to an inch and a half long. Now the bad news he said that to replace it the whole top end would have to be taken apart and a a rebuild done. Does this make sense? I saw the pieces of metal and the plastic myself so I know they were definitely in the pan. It looks like this will be a very big and expensive job. The strange thing is that the bike runs like its brand new. Not a single problem with it. Wouldn't having these metal pieces sheared off and a piece of the chain tensioner broken off effect the operation of the bike? If anyone has any info or thoughts on all this it would be much appreciated. Thanks all.

Here is a picture of what was in the bottom of the oil pan

My guess is the piece is one of these from this diagram. #14, 15 or 16. Which one do you guys think this is and will the replacement of this be a difficult and expensive job? Thanks for any help/advice.