A small problem

[GsBike]

I'm stumped!

The previous owner of my 79'XS11F stripped the fill port bolt for the rear drive - where I should check and fill the rear drive oil. The allen wrench just spins!! The problem is its basically flush so I can't get a wrench on it's edge. I looked into getting a sheared bolt extractor but it calls for drilling out the center and installing the reversed treaded plug. I don't want to drill the fill port bolt because that will get metal filings in the oil.

Any ideas? It's not rusted - just looks like the PO tightened it too much and then stripped it trying to get it off.

[skids]

Re: A small problem

The plug is more than a half inch long, I think. I think I used a chisle on one of mine to get it off. There was no room to get a vise grip on it. Replacements are 5.00 or so from Yamaha. I think you could use an easyout if so inclined.

[newmaac]

I agree, you should be able to drill a hole in it and use an easyout.
It would be good to confirm the length dimension first though, so that you don't drill through it and drop shavings into the works.

A little penitrating fluid could't hurt.

If all else fails, there are used final drives available. I have several, and could set you up with one for a reasonable amount.
Good luck

[Ken Talbot]

I agree there's not much of a lip around the head of the bolt, but there is just enough to grab with a decent set of slip-joint pliers with fresh, sharp teeth on the jaws. DAMHIKIJD

[Bud Manley]

Ok what exactley does DAMHIKIJD mean?

[CMA1]

One thing that has worked for me in the past, with similar situations is a 2"cutting disc on the Dremel.
Cut a slot into the bolt face and you have a spot to insert a broad blade screwdriver with visegrips attached to the screwdriver shaft. Just be careful to not cut into the drive housing.

[xssiveone]

Originally posted by Bud Manley
Ok what exactley does DAMHIKIJD mean?

I think it means "Don't Ask Me How I Know, I Just Do!!"

[billz28]

I did the same thing to my bike several years ago. I talked to the local Yamaha K&N guy. Mine wasn't leaking and he had me wait until I was putting a new tire on and remove the entire rear drive. Took into him and he got the plug out and installed a "helicoil". On the bench he was able to completely clean all parts and get all the metal shaving out. I don't remember exactly what he charged, but it was a very small amount - I believe it was about $25., mainly because it was off the bike.

Wild Bill
'80LG Midnight Special
'03 ST1300A

[strom]

A broad screwdriver would work... especially the impact wrench on the other end.
I know you can do it... just take a bigger hammer. Works for me.


LP

[TopCatGr58]

Another approach.

Just a thought, how much are your easy outs? I know they have a bit of a taper, but I also know they are kinda brittle and I have broken a few. If the tip was cut/broken off of a particular easyout that comes close to the size, wouldn't it then fit into the modest recess enough to possibly grab the inside without any drilling of the plug!? Good luck.
T.C.

[KurtG]

I have removed stripped allen head fasteners by gently tapping a Torx driver that is a tight fit into the allen head. It usually grips well enough to get the fastener out.

[GsBike]

Easy out not easy

o.k. I got an easy out from the auto store (it included a drill bit and a reversed threaded plug). I got the size that was slightly bigger than the stripped allen wrench hole. I took the forward fill cap off and measured it's thickness. I put tape on the drill bit as a guide so I wouldn't drill through the rear cap. I drilled as deaply as I could and then inserted the plug. DAMN!! it stripped again. As top cat said, they are tapered and only the upper part of the plug gripped the edges of the drilled hole. It looks like they were designed to go all the way through the bolt with it's tip extending out the bottom.

I think I will try CMA1's idea and cut a slot into the cap with the dremel - I'm concerned that since it's almost flush with the housing I won't get a very deap slot cut. Maybe that in combination with some sharp slip-joint pliers. I am weary of pounding in it thinking I might crack something.

I might take you up on your offer Newmaac for a used final drive.

[Bob Falter]

Grind the end of the plug off about half the depth of the hole and try it again. Tap it in as you use some pressure trying to turn it out.

[Jeff]

You could also try tack welding a socket extention or something of that sort to the surface. I had to weld a socket onto my oil filter bolt to get it out originally.

[fusionking]

Might go ahead and purchase the replacement plug now that way you won't be freaked out about not being able to ride and all. I'd probably just use a chisel on the edge in the direction to loosen if I had already stripped it. Don't care much for easy-outs.