any tips to stop primary drain plug from leaking - tried thread tape and also tried loctite 569 - hydraulic sealant.............................any tricks out there????    

I always replace the o-ring every time, because if you take them off and have a close look they are nearly always stuffed.....

and I dont use any sealant .

depends on what year bike you have( I think ) I know with mine (2001 model) the drain plug has no torque spec. Make sure there's no oil residue by wiping it with as best as you can, apply your thread sealer and screw it in by hand ony at first so you don't strip the thread. then use a torx till you feel a bit of resistance. If it still leaks, tighten it a bit more, Hope this helps. Had the same issue with mine,

mines just a tapered pressure plug - ive not seen one of these with an o'ring....

Be carefull not to overtighten the tapered plug, as they can crack the primary so I've read.
Tried liquid Teflon pipe sealer ?

bit of a worry, it does sound like there could be a crack. everything else you've tried should have worked

thanks everyone, i'll have another go on the weekend and double check for a crack.

cheers, Wilso.

My pick would also be checking for a crack .... have used Loctite hydraulic thread sealants for years and it is pretty awesome stuff, in my experience it usually still seals even if there is still a bit of residue ??? obviously cleaner is still better though!

speedzter is right tapered plugs can/will crack housings when overtightened, espically alloys.

ive got my hands on some high pressure pipe sealant from loctite also - im gunna giv it a go this week , see how that goes.

Plumbers tape....      & DONT screw in in 2 far...   it will hit ya primary chain...  & or crack ya primary cover...   

I use Thead Sealer from Permatex available from Super Cheap, just put it on that last few threads so it does not egress to the transfer case.

tapered plugs are the problem, we have trouble with them at work (mining hyd) all the time - and especially since the primary case is softer than the plug - every time they go in a little further which leads to the plug bottoming out and therefore only a matter of time and heat before whatever you put on the plug is bypassed.

You'll be fine with the pipe sealant. Again, just remember to screw in with your fingers first so you don't strip the thread. Also worth investing in some spare drain plugs, I have 2 spares at home, just in case the magnetic tip at the end gets knocked off. You'll find about 2/3 of the way is all you may need to screw it in ( with sealer ) before the leak stops.

used thread tape and some of the pipe sealant - works so far....

the thread tape worked on mine and is still strong - however my old mans bike was leaking so tried thread tape again and the new HP pipe sealant by loctite.