Welcome to NESR! Most features of this site require registration, including replying to threads, sending private messages, starting new threads, and uploading files. Click here to register.

Page 1 of 2 12 LastLast
Results 1 to 25 of 27

Stripped oil drain plug of doom. What do I do?

  1. #1
    beige camry attack mojobreakfast's Avatar
    Join Date
    Aug 2008
    Location
    Salem, MA
    Age
    44
    Posts
    398

    Angry Stripped oil drain plug of doom. What do I do?


    Multistrada 1200. The picture below is mine, after the damage was done. I was attempting to remove the drain plug (the plug off to the right) in order to change the oil. Instantly stripped the recess. Bolt never even budged. How do I get this @!$^&@$ thing off. I'm afraid using an easy out will get me dangerously close to the threading on the sump. I tried threading one in (by hand) and then chickened out. The only thought I have, besides taking it to the dealer, would be to JBWeld a bit in there, that I could then use to attach a socket wrench.

    Stripped oil drain plug of doom. What do I do?-p1050402-jpg

    0 Not allowed! Not allowed!
    no bikes currently

  2. #2
    Lifer SteveM's Avatar
    Join Date
    Aug 2009
    Location
    Norwell, MA
    Age
    60
    Posts
    2,569

    Re: Stripped oil drain plug of doom. What do I do?

    Ok, here's the obligatory, "The bike is now ruined, I'll take it off your hands for $100." post.

    Good luck, I hate it when a hex wrench slips. There have to be better answers for applicants like this, like a real hex bolt.

    0 Not allowed! Not allowed!

  3. #3
    Lifer jasnmar's Avatar
    Join Date
    Mar 2012
    Location
    Chichester, NH
    Posts
    4,252

    Re: Stripped oil drain plug of doom. What do I do?

    I'd prolly start by trying to find a torx that was just bigger and "gently tapping" it in. The sort that fits on a ratchet would be best.

    Hard to tell from the image... is the head of the plug flush with the face of the sump?

    0 Not allowed! Not allowed!

  4. #4
    Lifer catamount's Avatar
    Join Date
    Sep 2006
    Location
    Colchester, VT
    Posts
    1,388

    Re: Stripped oil drain plug of doom. What do I do?

    I've had good luck using a sacrifical torx bolt just slightly bigger than the hex. Drive it in there straight, it'll contort to fit, and then use a large breaker bar to get the plug out.

    0 Not allowed! Not allowed!
    Last edited by catamount; 08-10-12 at 05:51 PM. Reason: treed

  5. #5
    BMW track whore e30addict's Avatar
    Join Date
    Jun 2008
    Location
    I93/495
    Age
    44
    Posts
    6,369

    Re: Stripped oil drain plug of doom. What do I do?

    Is there enough of an edge to grab the bolt with a big pair of vise grips? Orient the grips parallel to the ground.

    0 Not allowed! Not allowed!
    2012 Tiger 800 XC

  6. #6
    Lifer G21forme's Avatar
    Join Date
    Jun 2008
    Location
    Lakes
    Age
    40
    Posts
    5,326
    I'm not sure what size it is but you could try tapping in a standard size allen socket if it's just slightly larger. If not I've had good luck with easy outs .

    0 Not allowed! Not allowed!

  7. #7
    beige camry attack mojobreakfast's Avatar
    Join Date
    Aug 2008
    Location
    Salem, MA
    Age
    44
    Posts
    398

    Re: Stripped oil drain plug of doom. What do I do?

    Unfortunately, there's not enough "edge" to use any kind of pliers on this thing. There's well less than 1/4" of an inch to play with, and that includes the crush washer.

    I did try tapping in a couple of up size allens/torx and they all just spin as soon as I put a wrench on them. I am probably not tapping them hard enough but I really don't want to be wacking away on my (aluminium) sump too hard.

    Any thoughts on the idea of JBwelding a torx bit in there? Another suggestion I have seen is to dremel a notch across the head of the bolt in order to use a screwdriver but I'm having a hard time thinking I could pull that off successfully.

    0 Not allowed! Not allowed!
    no bikes currently

  8. #8
    BMW track whore e30addict's Avatar
    Join Date
    Jun 2008
    Location
    I93/495
    Age
    44
    Posts
    6,369

    Re: Stripped oil drain plug of doom. What do I do?

    I wouldn't bother with the notch. Doubt you'd get enough torque.

    The JB weld thing is a great idea. I've used that method successfully before on a gear box drain bolt that was stuck in pretty much the same way.

    0 Not allowed! Not allowed!
    2012 Tiger 800 XC

  9. #9
    beige camry attack mojobreakfast's Avatar
    Join Date
    Aug 2008
    Location
    Salem, MA
    Age
    44
    Posts
    398

    Re: Stripped oil drain plug of doom. What do I do?

    Quote Originally Posted by e30addict View Post
    I wouldn't bother with the notch. Doubt you'd get enough torque.

    The JB weld thing is a great idea. I've used that method successfully before on a gear box drain bolt that was stuck in pretty much the same way.
    What are the potential downsides? I guess the bit could get broken off when I go to turn it, and then I'd be even more screwed.

    0 Not allowed! Not allowed!
    no bikes currently

  10. #10
    BMW track whore e30addict's Avatar
    Join Date
    Jun 2008
    Location
    I93/495
    Age
    44
    Posts
    6,369

    Re: Stripped oil drain plug of doom. What do I do?

    You'd more than likely just crack the JB Weld and the bit would slip out like it's doing now. You can try the EZ Out deal and see if it will spin out.

    Worse case? You'll have to drill it. Cleaning that up would suck.

    A shop is not going to do anything different than you would do. They just have more experience at it.

    0 Not allowed! Not allowed!
    2012 Tiger 800 XC

  11. #11
    Resident Turkey Tricky Mike's Avatar
    Join Date
    Jun 2005
    Location
    The burbs... where dreams go to die
    Posts
    5,946

    Re: Stripped oil drain plug of doom. What do I do?

    get your angle grinder (or a Dremmel) with a thin cutoff wheel... grind/cut a slot clean across the center. (You already need a new drain bolt). Just be careful not to cut too deep and into the case. Imagine you're trying to create a surface for a REAL big flathead screwdriver. What you want is a nice clean groove so you can tap it loose with a hammer and a (sharp!) punch... Line it up so you're tapping the bolt counter-clockwise (remember it's upside down) and use the hammer/punch to tap it loose. Work close to the edge of your groove... The further away from the center is where you have the most torque.

    I've probably done this 100 times. It's VERY effective when done right. The only downside is your punch possibly deforming the groove so much that you start slipping every time you strike the punch with the hammer. That's where a nice, sharp punch helps. It bites instead of slips. Also remember that one groove gives you two edges that you can use to tap the bolt counter-clockwise. If you trash both edges another groove perpendicular to the first one gets you two more. In my experience I've never needed more than one. The technique really works on the type of bolt pictured. It's due in a large part to the shock provided by the hammer strike. Most often that bolt just needs to break free... once loose it spins right out.

    1 Not allowed! Not allowed!
    Last edited by Tricky Mike; 08-10-12 at 08:23 PM.

  12. #12
    Infected Slyder's Avatar
    Join Date
    Jul 2007
    Location
    Concord, NH
    Age
    43
    Posts
    2,685

    Re: Stripped oil drain plug of doom. What do I do?

    I'd have to imagine tack welding a bolt or even a nut to it would work to, kinda like the JB weld idea, less chance of breaking. Welding a nut to the face of that bolt and you'd be able to re-use it as well as use a socket to remove it next time.

    The dremmel and cutoff wheel making it into a flathead screw sounds slick though. And re-useable.

    0 Not allowed! Not allowed!

  13. #13
    beige camry attack mojobreakfast's Avatar
    Join Date
    Aug 2008
    Location
    Salem, MA
    Age
    44
    Posts
    398

    Re: Stripped oil drain plug of doom. What do I do?

    I appreciate all the suggestions. Mike's idea of grinding a slot into the thing and tapping it out sounds solid. There's just not a lot of material to work with there, though, because of the type of the bolt (nearly flush with the sump). It's also a pretty tight space to work in. I'm a hack so I'd probably screw it up. I'm done screwing with it for the night, guess I'll sleep on it...

    0 Not allowed! Not allowed!
    no bikes currently

  14. #14
    Member jayth's Avatar
    Join Date
    Aug 2009
    Location
    N.H.
    Posts
    230
    I am just going to throw this out here I assume that you have changed oil before so you understand the drain plug is upside down therefore if you're using a ratchet in Lefty Loosy continue trying with the mentioned methods as a career auto technician I also have found a little impact to be beneficial in these situations get the best purchase you can with the ratchet and strike the handle with a dead blow.... even if you hamfisted it at the last oil change it shouldn't be that tight.... I am off tomorrow PM me if you need further assistance

    0 Not allowed! Not allowed!

  15. #15
    Unsafe at any speed GNTurbo6's Avatar
    Join Date
    Apr 2008
    Location
    Boston, MA
    Posts
    1,134

    Re: Stripped oil drain plug of doom. What do I do?

    Hammering a in nice strong torx socket is probably the best way to go. I've had to do it on my rotor bolts. I don't know how much room you have under the bike though.

    0 Not allowed! Not allowed!
    Friends don't let friends wave to Can Ams

  16. #16
    Lifer golden chicken's Avatar
    Join Date
    Nov 2011
    Location
    Fitchburg, MA
    Posts
    1,544

    Re: Stripped oil drain plug of doom. What do I do?

    If you are going to use a dremel, you can try cutting flats for a wrench. Or, you can try to cut off the crush washer to alleviate the pressure on the threads.

    0 Not allowed! Not allowed!
    What's the difference between a bolt and a screw?
    First you screw, then you bolt.

  17. #17
    I am Dead now
    Join Date
    Oct 2009
    Location
    The tax State of the Nation
    Posts
    191

    Re: Stripped oil drain plug of doom. What do I do?

    Is this drain bolt a "Torx" bolt or is it a "Allen" bolt? Also where did you get the tool from your bike's tool kit? I have found tool kits from bikes are of poor quality. The best tool Company I have found for allens & torx is "Wiha" they are made with tungsten so the edge of the tool stays sharp & doesn't round off the bolt.

    Someone here suggested to take a sacrificial Allen/torx wrench & using JB weld on it. I would recommend you buy a socket torx/allen tip instead and JB weld it in. Of course you will need to use something to support that tip in the bolt while the epoxy is drying for 24 hours. A cheap hydraulic bottle jack would work great. Now you will have the ability to add a ratchet extension on that tool to get it at a comfortable distance away from your exhaust pipes, probably a 6" would be about right.

    I have never seen JB weld give way, just make sure you clean the surfaces to be glued with alcohol.

    Good luck!

    0 Not allowed! Not allowed!
    Last edited by ptk-napalm; 08-11-12 at 05:47 AM.

  18. #18

    Re: Stripped oil drain plug of doom. What do I do?

    I was about to write ..... the same response as mike did!

    I do this a lot on car brake rotors, when they have small screw that hold the rotor on. It also sometimes helps if you drill a small hole thru the center of the bolt. Go slow and easy and don't break the bit, and just make sure you go through the middle and not near the threads. Obviously this is going to drain the oil, but it should relieve pressure and give the bolt a bit of room to compress when do the dremel idea (if it doesnt work right away).

    0 Not allowed! Not allowed!

  19. #19
    Wanker 2v2Ducati's Avatar
    Join Date
    Aug 2008
    Location
    Medford, MA
    Posts
    528

    Re: Stripped oil drain plug of doom. What do I do?

    I had same happen to my 900SS. I used a chisel and hammer, made a notch near edge of circle and slowly tapped the chisel until i loosened the plug.

    0 Not allowed! Not allowed!
    Like I said they say, nothing stops a party barge.

    97' Ducati 900SS - Sometimes runs

  20. #20
    beige camry attack mojobreakfast's Avatar
    Join Date
    Aug 2008
    Location
    Salem, MA
    Age
    44
    Posts
    398

    Re: Stripped oil drain plug of doom. What do I do?

    Appreciate all the advice guys. I put the bike back together and I'm just going to see about having Seacoast take care of this for me. I know I'll pay for it, but I'd rather not get myself potentially in further over my head on a 3 month old bike...

    0 Not allowed! Not allowed!
    no bikes currently

  21. #21
    Lifer SteveM's Avatar
    Join Date
    Aug 2009
    Location
    Norwell, MA
    Age
    60
    Posts
    2,569

    Re: Stripped oil drain plug of doom. What do I do?

    I'm not sure how the Italians are about this, but the Germans would take the bike away from you and tell you that you cannot have another one as you are unworthy of their engineering.


    The folks at Seacoast are great and will take care of you. Make them smile by telling them you'd like to enter the knucklehead of the month competition. I've always found that beginning with, "Hi, I'm Steve and I've done something really stupid. Can you help me?" works pretty well.

    ...and I've said it more than once!

    2 Not allowed! Not allowed!

  22. #22
    Lifer golden chicken's Avatar
    Join Date
    Nov 2011
    Location
    Fitchburg, MA
    Posts
    1,544

    Re: Stripped oil drain plug of doom. What do I do?


    1 Not allowed! Not allowed!
    What's the difference between a bolt and a screw?
    First you screw, then you bolt.

  23. #23
    Redistribution Supplier
    Join Date
    Nov 2011
    Posts
    134

    Re: Stripped oil drain plug of doom. What do I do?

    I recommend replacing the bolt with this if you can,when you get it out.

    http://www.stahlbus.com/info/en/prod...l-drain-valves

    0 Not allowed! Not allowed!

  24. #24

    Re: Stripped oil drain plug of doom. What do I do?

    "Thus, the oil change makes fun!" - from the product above. Ive come across some different variations of things like that during work, none of them ever had leak.

    0 Not allowed! Not allowed!

  25. #25
    Lifer 01xj's Avatar
    Join Date
    Jun 2010
    Location
    CT
    Age
    34
    Posts
    1,439

    Re: Stripped oil drain plug of doom. What do I do?

    Quote Originally Posted by Tricky Mike View Post
    get your angle grinder (or a Dremmel) with a thin cutoff wheel... grind/cut a slot clean across the center. (You already need a new drain bolt). Just be careful not to cut too deep and into the case. Imagine you're trying to create a surface for a REAL big flathead screwdriver. What you want is a nice clean groove so you can tap it loose with a hammer and a (sharp!) punch... Line it up so you're tapping the bolt counter-clockwise (remember it's upside down) and use the hammer/punch to tap it loose. Work close to the edge of your groove... The further away from the center is where you have the most torque.

    I've probably done this 100 times. It's VERY effective when done right. The only downside is your punch possibly deforming the groove so much that you start slipping every time you strike the punch with the hammer. That's where a nice, sharp punch helps. It bites instead of slips. Also remember that one groove gives you two edges that you can use to tap the bolt counter-clockwise. If you trash both edges another groove perpendicular to the first one gets you two more. In my experience I've never needed more than one. The technique really works on the type of bolt pictured. It's due in a large part to the shock provided by the hammer strike. Most often that bolt just needs to break free... once loose it spins right out.
    Came here to say the same. I have used this technique a few times as a last resort. Give yourself a nice clean cut and make sure your flathead tool has a nice big "bight" into the slot so you don't strip it a second time.

    0 Not allowed! Not allowed!

Page 1 of 2 12 LastLast

Similar Threads

  1. Magnetic Oil Drain Plug
    By Kazinator in forum Bike Maintenance
    Replies: 22
    Last Post: 09-14-11, 05:36 PM
  2. Burton Doom 157 Snowboard w/brand new bag
    By Quigs in forum For Sale
    Replies: 5
    Last Post: 11-04-10, 02:31 PM
  3. I can't get my 'effing drain plug loose...
    By Femmekat in forum General Bike Related
    Replies: 47
    Last Post: 08-04-09, 07:33 PM
  4. POLAR BEARS OF DOOM
    By richw in forum Controversial Topics
    Replies: 6
    Last Post: 12-28-06, 03:23 PM
  5. stripped drain plug
    By Gangsta SV in forum Bike Maintenance
    Replies: 11
    Last Post: 09-12-05, 02:14 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •