HELP! Need Suggestions

[Elvis]

Hey everyone, it is cold here so I thought I would change the oil in the ole girl and hook up the trickle charger cables. The charger was easy taking less that 10 minutes, the oil is still not changed.

My dealer replaced a detent spring back last summer and of course had to change the fluids when doing this. After putting the bike in the chock I popped the front sump allen bolt loose and then went for the oil plug, OMFG!, it is in there tight, I pull, push even bump the ratchet with a hammer, no good. I ended up destroying the inside of the bolt. I go to the parts store and do not like my easy out options so I buy a larger 3/8 " allen socket and bring it home and grind it down to fit in the new hole created by the 8mm allen wrench. Still no success, I plan to try a small chisel and hammer tomorrow to see if I can bump it out.

Anyone else have any ideas?

 

[GPMAZ]

Sorry, no good suggestions. Other than to take it back to the dealer and let them fix their screw up.

 

[Elvis]

Sorry, no good suggestions. Other than to take it back to the dealer and let them fix their screw up.

Thanks, they are two hours away , 2.5 since the Delta Mariner took out the bridge that crosses Ky lake.

 

[rainman]

try warming the engine up before trying to take the plug out sometimes it makes it easier just my 2 c worth

 

[albertaduke]

or as a last resort get an extractor kit and thread it out

 

[Elvis]

try warming the engine up before trying to take the plug out sometimes it makes it easier just my 2 c worth

Thanks Rainman, I did let it run long enough to make it pop when turning it off.

 

[Elvis]

or as a last resort get an extractor kit and thread it out

Bought a Kobalt extractor this morning and some small chisels, my buddies and I think the crush washer has it seized up from being in too tight, will be spraying some penetrating oil in under that that I used to use to free up old tractors.

 

[Dennsell]

If you know a professional welder/fabricator get them to warm around the plug to expand the thread it will also break any thread lock that maybe someone used..

WARNING..
Please don't attempt this yourself unless you are experienced with gas gear and flame torches...Oil and Fuel evaporate into explosive gas very quickly.
Flambe' isn't a good look

Please think before doing this and consider the consiquences

 

[roosie]

sumps

be very careful,you might break the sump..can you get vice grips [curved] onto the sump plug.or weld a nut onto the sump plug.this is probably better than hitting the sump plug with chisels.after you weld a nut to the plug use a long breaker bar 1/2 inch.crack it slowly.you fill things much better with a breaker bar.

 

[Gothlander]

Instead of using heat you can use a can of compressed air that will shrink the plug. But it sounds like the steel plug has galled with the alloy and more than likely will remove the thread from the sump when it is removed. I think a zinc based anti seize should be used with stainless steel in alloy cases. If you use the cold method sometimes tightening the plug slightly (before undoing) will help prevent the thread coming out.