rebuild questions

[RS Thornton]

Working on my special and having a tough time getting the gear oil plugs out. Bike was stored for 15 years so alot of things are tight, been using WD 40, tapping the plug etc. Every day a try again for a few minutes and it feels like I am close to stripping either the allen head or the ratchet gears. Any suggestions?

Also, I dropped the tank off at a local radiator shop for acidizing and lining. The guy warned me that they were not responsible if acid damages the paint. Anyone else get this warning, or do I live in an area with too many lawyers?

[dragxs11]

I think the gearbox plugs are a common problem. I stripped mine out too, and had to kill it with a visegrip. The good news is Yamaha dealers can still order them for you.

[Hobbit]

Whenever I have to work on a really tight allen bolt, I put a little valve lapping compound in the head of the bolt. This gives the allen wrench a better grip. Also try a hand impact instead of a ratchet. They aren't expensive and they come in very handy.

[Ken Talbot]

I got mine loose the first time by using a pair of long-handled pliers with fresh, sharp teeth. Yes, it kind of chewed the bolt a bit, but at least they came out. When you go to put them back in, use a dab of anti-seize compound, a fresh crush washer, and don't use gorilla force to crank it on. BTW - the washer off an old sparkplug will fit as a new crush washer, as long as those weren't installed by a gorilla too!

[tfm3]

If you live in the western hemisphere, then you live in an area where there are too many lawyers.

[pgg]

Swing a steel pipe off the allen key.

[RS Thornton]

Did it
Finally gave up being Mr nice guy and knowing that craftsman has a replacement policy I had at it. Big bang and I am sitting on my butt thinking something just broke, but no broken ratchet, no stripped plug. Thanks for the tips, and I am using an spark plug washer on these.