Stuck Filter Bolt and FD filler plug

[James England]

If you really get desperate re the FD filler plug, I'd drill it out, whilst getting someone to hold a vacuum cleaner hose next to the drill bit. If you use a large drill bit, just under the diameter of the plug, you'll find a vice-grip will succeed in moving what's left in there. I'd swill out the FD with something though, jut to get any swarf that the vacuum cleaner might miss.

Of course, you'll need a new FD filler plug but, from what you've said, yours is pretty wrecked now.....

[WMarshy]

The biggest issue with getting these plugs out is you really need hit them with an impact blow either from a hammer or from an impact wrench. If you have them rounded off good then its going to be a battle. For what its worth, I would find someone who is willing to weld a nut onto the plugs while on the bike. You should disconnect the battery and the TCI module under the seat before welding though.

[benxs1100]

If you do have to drill out the plug you make sure you use a really sharp bit and smear some grease on it. The shavings will follow the grease and keep them out of your FD.

[BA80]

with the FD whining like it is, I don't wanna run it any more and risk a cato.

Sorry to be the bearer of bad news Lb but if it's whining it's most likely too late anyway. Bite the bullet and get another.

I suggest an 850FD but if you want a stocker I have 3 or 4 here, I'll give one up cheap.

[oldyam80sg]

I once took the filter bolt and using a dremel tool with a disc actually ground it flush so the bolt didn't have much of a head on it-actually no head, and the unit just came off.But you have to know how much to grind away if not you will have to buy the housing.

[Lbrown311]

Thought about grinding it off and just slipping the housing over it, then getting the rest of the bolt out and replacing it. Not sure what I wanna do yet. Just got home to check all the new posts. Might take it to work with me and see if the metal shop behind me will try it

Also, don't the FD's normally whine. It was fine when I got it, just a bit more now. Only thing I changed was to clean out and re-grease it after putting the new rear tire on. Why would it be too late? How would I go about checking to make sure. I don't wanna buy one just to buy one. PM me on a price you are thinking BA80.

[BA80]

Like I said, I recommend replacing it with an 850 FD but if you want a stocker they are practically giving them away on fleabay.

http://motors.shop.ebay.com/i.html?_...506.m270.l1313


The 850 FDs as well. If you switch you want an 80 or newer for easy installation.

http://motors.shop.ebay.com/i.html?_...506.m270.l1313

[jetmechmarty]

As many people have swapped to the XS750 final drive, it seems to me, someone should be willing to give you one. If not, as stated, they're cheap.

I'm not offering, because I'm not making the swap.

Marty (in Seattle)

[BA80]

As many people have swapped to the XS750 final drive, it seems to me, someone should be willing to give you one. If not, as stated, they're cheap.

I'm not offering, because I'm not making the swap.

Marty (in Seattle)

Heh heh........thanks for your input Marty.

[Lbrown311]

Well I found out the whine was from my exhaust baffle and not the FD WHEW! Got the FD filler plug out with an EZ out without drilling all the way thru it. Stuck it tight and gave it a good whack with a hammer and it popped free. I got the gear oils changed to Royal Purple as I heard good things about it and agree with the GL-5 gear oil. Now I have to figure out the Filter bolt. Tried the tapping method and a vise grip but there is just really no space down there without popping the headers off. I think I will see if I can get a nut welded on and get it out that way. Anyways I am half way there, and glad to find out the FD was in good shape. Oil in both was pretty dirty as well as the magneto plugs, so...glad I got them changed. Hopefully reduces the stock oil whine like people say it does. Can't wait to get the ColorTune and get her runnin perfectly Thanks for the help guys. Much appreciated as always.

Both bolts will be replaced with new ones, but for the mean the filler plug on the FD is just snug and not leaking.

[BA80]

You will never get rid of all the whine Lb. That's just part of the XS11 package.

ORielly's has this too..http://www.oreillyauto.com/site/c/se...rd=nut+remover

I know it says it's $45 but they also have a house brand of the same tool that runs about $20. These have worked very well for me removing stripped or broken exhaust studs. Should work on your filter bolt too.

They are designed so the harder you turn them the tighter they bite.

JAT

[Lbrown311]

Sweet BA80 I might have to check out if they maybe rent them. Wouldn't be a bad tool to own tho I will check tomorrow and prolly rent the compression tester that they rent for free and see whats goin on inside there.
Thanks for the tip

[James England]

As many people have swapped to the XS750 final drive, it seems to me, someone should be willing to give you one. If not, as stated, they're cheap.

I'm not offering, because I'm not making the swap.

Marty (in Seattle)

Aha yes, I agree...but..... the many people have posted doubts about the 750FD swap and doubt the longevity of the 750FD on the 1100 etc. So, even generous people like me, who are currently tearing about and loving their FD swap, will probably hoard their OEM drive in case anything goes wrong. Or are you saying you now have such faith in the swap that you don't think the 750FD will blow up? Please clarify..... if the swap is no good, as I think you've said before, you really should be recommending that we keep them, not give them away, eh?

[Lbrown311]

I've heard enought to make my opinion on the swap and I won't be doing it. So if anyone wants to give away their original FD. I'll PM you my address

Plus I like to keep it as much stock as possible. Down the road I will consider a custom XS11

[cywelchjr]

Each has to make their own decision. It's interesting that even with the higher effective FD ratio of the standard bikes, the FD swap actually seems to be more popular on the standard models than on the specials by a small margin . Not sure why, as it seems that it would be more beneficial on the special than the standard for sure. I know if I get a special, the first thing I'm doing is hunting up a 750/850 FD for it. It's all about be comfortable and happy with YOUR machine, and doing the things that make YOU happy with it. Some seem to feel that a fork brace and fork emulators and special front springs and rear shocks are really important, and while I rate them up a ways, I don't ride hard, so it's not nearly as high on the list for me as it is for some. However, the spin on oil filter adapter was REALLY high on my list, so it's all about what's important to YOU (and while I'd like a nice seat cover, I'd rather ride, and my raggedy seat cover keeps the foam on the inside for the most part, and it's comfy, so until I can find a backup seat it stays as is) as it's not stock, so I can't get an off the shelf cover, it requires finding a shop to do a custom cover and having no seat and no bike while they work on it, not something I'm willing to do while it's possible to ride (which can be a problem with there being little to no downtime here in sunny Cantafordya) .