Final drive filler cap wont budge

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  • madmax-im
    Master of XSology
    • Sep 2007
    • 6751
    • Southern Comfort...Wendell NC

    #1

    Final drive filler cap wont budge

    Randy and I are going to do surgery on MadMax tomorrow...in doing the pre-surgical prep..one of the things to do is drain the middle drive and final drive fluids.With a 6mm allen tool the filler cap on the final drive wont budge.So I tried to heat the bolt with a torch using Mapp gas...Ionly keptt the heat on it for a long minute...it wasn't enough..net result...no change...SO my question is...How long should I heat up the bolt before trying to loosen it?Any other method more effective...???
    1980 XS650G Special-Two
    1993 Honda ST1100
  • red bandit
    XSive Maximus
    • May 2005
    • 950
    • central michigan

    #2
    You can use a hammer and chisel to try to turn it will someone else uses the allen wrench. Randy nows how.
    79 F full cruiser, stainless brake lines, spade fuses, Accel coils, modded air box w/larger velocity stacks, 750 FD.
    79 SF parts bike.

    Comment

    • randy
      XS-XJ Guru
      • Dec 2003
      • 4521

      #3
      Ben, if you're using heat, don't heat the bolt, that will make it tighter as the heat expands the bolt. let everything cool, then use heat on the HOUSING around the bolt. When you're ready to wrench it, tap the bolt first with a small hammer. This method always work for me.

      Comment

      • 79XS11F
        XS-XJ Super Guru
        • Jul 2006
        • 3563
        • Ottawa, Ont. Canada

        #4
        And when you put it back in use a little bit of anti seize on the threads and torque it only to the manual specs.
        Rob
        KEEP THE RUBBER SIDE DOWN

        1978 XS1100E Modified
        1978 XS500E
        1979 XS1100F Restored
        1980 XS1100 SG
        1981 Suzuki GS1100
        1983 Suzuki GS750S Katana
        1983 Honda CB900 Custom

        Comment

        • Ken Talbot
          XS-XJ Super Guru
          • Jun 2002
          • 4251
          • Revelstoke, BC

          #5
          And use a new crush washer too. A gently used washer from a sparkplug will work, as will a nylon washer if you can find one that size.
          Ken Talbot

          Comment

          • mro
            XS-XJ Super Guru
            • Oct 2005
            • 4276
            • Hayward, California

            #6
            How long should I heat up

            What they said.
            Aluminum expands faster with less heat than steel.
            One minute should be enough...altho
            guy brought his XS to my shop because he could not get the filler plug out. First tried getting it out with an impact goody, then with propane tourch and impact. Wound up using hammer/chisel


            mro

            Comment

            • mason79
              XS-XJ Guru
              • Mar 2006
              • 1351
              • los angeles, ca

              #7
              rode for a while to heat up the housing then try again worked for me. then use antisieze and don't over tighten
              "a good man knows his limitations" dirty harry
              History
              85 Yamaha FJ 1100
              79 yamaha xs1100f
              03 honda cbr 600 f4
              91 yamaha fzr 600
              84 yamaha fj 1100
              82 yamaha seca 750
              87 yamaha fazer
              86 yamaha maxim x
              82 yamaha vision
              78 yamaha rd 400

              Comment

              • madmax-im
                Master of XSology
                • Sep 2007
                • 6751
                • Southern Comfort...Wendell NC

                #8
                Thanks everyone for their input... I appreciate the value of experience...I will be heading back out to the garage now...
                1980 XS650G Special-Two
                1993 Honda ST1100

                Comment

                • madmax-im
                  Master of XSology
                  • Sep 2007
                  • 6751
                  • Southern Comfort...Wendell NC

                  #9
                  Dumb$### Award

                  Went out to heat up the housing around the final drive filler bolt and I followed previously given advice abt how to remove the bolt but in the process I managed to strip the head with the allen tool ...God I HATE allen heads...so not sure what to do in this case.I think I will wait for reinforcements...just goes do show you who should get the dumbsh## award for the month
                  1980 XS650G Special-Two
                  1993 Honda ST1100

                  Comment

                  • wa407mpp
                    XSive Maximus
                    • Jul 2007
                    • 717

                    #10
                    Impact driver.

                    Am I the only one on this site who owns an impact driver, they were invented for jobs like this, if you don't have one, buy one, it will save you a lot of work, frustration and striped parts.
                    Fastmover
                    "Just plant us in the damn garden with the stupid
                    lion". SHL
                    78 XS1100e

                    Comment

                    • Flatlander
                      XStremely XSive
                      • Jan 2008
                      • 288
                      • Michigan, Thumb

                      #11
                      Originally posted by randy
                      Ben, if you're using heat, don't heat the bolt, that will make it tighter as the heat expands the bolt. let everything cool, then use heat on the HOUSING around the bolt. When you're ready to wrench it, tap the bolt first with a small hammer. This method always work for me.
                      I've found that to work also, Randy.


                      And with two differenrt metals, I've also taken a ice cube to the bolt for a couple of seconds. This has helped I think.?.
                      What, dosen't every one have some cold ones on ice in the garage?
                      Flatlander

                      '81 XS11H

                      Comment

                      • mason79
                        XS-XJ Guru
                        • Mar 2006
                        • 1351
                        • los angeles, ca

                        #12
                        Re: Impact driver.

                        Originally posted by wa407mpp
                        Am I the only one on this site who owns an impact driver, they were invented for jobs like this, if you don't have one, buy one, it will save you a lot of work, frustration and striped parts.

                        good idea never thought of that, but i never said i was a good mechanic.

                        i may buy for for my stuck middle drive filler
                        "a good man knows his limitations" dirty harry
                        History
                        85 Yamaha FJ 1100
                        79 yamaha xs1100f
                        03 honda cbr 600 f4
                        91 yamaha fzr 600
                        84 yamaha fj 1100
                        82 yamaha seca 750
                        87 yamaha fazer
                        86 yamaha maxim x
                        82 yamaha vision
                        78 yamaha rd 400

                        Comment

                        • xschop
                          XS-XJ Guru
                          • Feb 2006
                          • 1794
                          • oklahoma city

                          #13
                          dremel

                          dremel a large slot and smack it CCW with a chisel. Been there.
                          MDRNF
                          79F.....Not Stock
                          80G......Not Stock Either....In the works

                          Comment

                          • 79XS11F
                            XS-XJ Super Guru
                            • Jul 2006
                            • 3563
                            • Ottawa, Ont. Canada

                            #14
                            Once you get that slot made in the cap heat the case up REAL good and apply some penetrating oil... let it cool and repeat. Then heat her up again and go at it with the cold chisel.
                            Rob
                            KEEP THE RUBBER SIDE DOWN

                            1978 XS1100E Modified
                            1978 XS500E
                            1979 XS1100F Restored
                            1980 XS1100 SG
                            1981 Suzuki GS1100
                            1983 Suzuki GS750S Katana
                            1983 Honda CB900 Custom

                            Comment

                            • ross
                              XSive Maximus
                              • Dec 2006
                              • 542
                              • see signature...

                              #15
                              madmax-im.....just a thought....if ya wanna spot freeze a bolt.....just go 2 the office supply store and get a can of air duster 4 your computer keyboard.....heat the hub area......then turn the air duster can upside down, use the spray straw, and it should spot freeze the head of the bolt.....spray until the bolt frost up.......(please use safety glasses as this is not something you want in your eyes!!!)......not sure if it will work, but will greatly improve the expansion differences between the hub and the bolt.....that and an impact driver should do it...if not, if u have a harbor freight in the area, get a cut-off wheel, cut the slot, and use the chisel with great care...as a last resort, drill it out, cut slots in the drilled out hole without touching the threads and using a chisel fold the walls of the plug into the hole......ross
                              rebel devil
                              1979 xs 1100f standard
                              authenic historical vehicle
                              42°36'23.52"N, 82°52'44.78"W
                              "I'M IN MY HAPPY PLACE"
                              "i got 14 jobs mon....you only got 1 job....you lazy bones mon"
                              "if you don't wrench on it, get behind me satan!"
                              '96 venture cct.....installed!
                              stainless, braided, pvc coated brake lines
                              i can translate...deustch, nederlands, 汉语, 漢語, français, ελληνικά, italiano, 한국어, português, русско, español and most importantly, 日本語....

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