Middle Gear Oil Filler

[kevinbarzotelli]

Hi Guys
i can't for the life of me undo the allen key filler for the middle gear oil.
i have hit the allen key with a hammer & tried grips , i've stayed on WD40 & it
wont budge. I've loosens the drain plug to (maybe) release pressure, but i don't want to drain the oil until i know i can undo the allen key filler hole.
Any help greatly appreciated.
Cheers All
Kev

[bikerphil]

Hammer and a cold chisel. Tap a groove in the side of the plug and spin it counter-clockwise. Works every time.

[trbig]

A recent thread on this problem...

http://www.xs11.com/forum/showthread.php?t=24105

Tod

[kevinbarzotelli]

Thanks Guys
All sorted.

[schpiff]

Still curious

I am not a machinist (but I did stay at some overpriced Holiday inn once).
I too have had probs with the fill and drain plugs being a devil to break loose even after being careful not to overtighten them.
I have always been able to "crack them loose" by applying pressure and giving a good sharp whack to the ratchet. I have used an allen wrench but its hard to get a good solid smack on them.
My question for the machinist guys:
What makes em stick so bad?
Is it the flex of the head of the plug?
The threads themselves seem to be cut fairly deep and turn easy.
I am thinking I will take that advice earlier and next time I have em out I will
use some teflon or something to make it a bit easier as the buggers do stick tight.

[motoman]

steel plug.........aluminum case..........bad combo. Find a thin fiber washer that fits perfect I.D..........or do like I do........snap a small pair of vice grips on outer edge of plug.......tap vice grip handle right smartly with a hammer.........works every time without slipping vice grips. Leaves a couple vice grip notches for next time. No known leaks, drain and fill to proper level with 75-140 Royal Purple and forget it! Have done the same with final drive, and between the two lost the annoying whine plus notice final drive case stays cooler. That's a good thing, less friction= less wear.

[CatatonicBug]

I just add anti-seize to the threads. My final drive fill-plug has an external head, so I just use a socket to open that one.

[morticiaann]

Middle Engine Oil Fill Plug

Drill the plug and use a screw extractor. I noticed nobody has told you about heat on frozen screws. Use a torch because metals expand and contract according to temperature. Also try an impact wrench (which might come with the 6mm allen wrench). If worse comes to worse; take the engine out of the frame and drill the plug out and cut new threads.

[Ivan]

Drill the plug and use a screw extractor. I noticed nobody has told you about heat on frozen screws. Use a torch because metals expand and contract according to temperature. Also try an impact wrench (which might come with the 6mm allen wrench). If worse comes to worse; take the engine out of the frame and drill the plug out and cut new threads.

Instead of pulling the engine, just yanking the middle drive would be much easier.

[subike]

Would it be worth the effort to see if somebody could find a plastic plug that would do the job as a mod?
Seeing as this problem is consistant across all models, suely we could find a compatable plastic cap off of another bike.
Or maybe look in the plumbing depot of a hardware store for a brass one. worth the effort?

[DGXSER]

Someone put a replacement plug in my middel drive and all it does is leak. I've used teflon tape on it, and tightened it up good more than once, still leaks. I'd like to get ahold of the stock plug to put back in it if that would stop the leaking!

[Ivan]

They don't need to be much more than just snug when you put them in. It helps the next time you take it off if it hasn't been ham handed on the install.

[bikerphil]

I'd like to get ahold of the stock plug

Still available new from Yamaha...

Plug P/N 90340-14046-00 $5.17

Gasket P/N 214-11198-01-00 $.99

[DGXSER]

Thanks Phil!

I'll get in touch with the dealer I am buying my clutch springs form and add that to the order.

[wa407mpp]

You don't have to pull the engine to pull the middle gear assembly, You can pull out easily after removing a few things in the way and twisting it around a little.