Help!!! Stripped Oil Drain bolt!

Okay it looks like a fairly bad design so I can't be the first person that this happened to. Here's the low down, '96 CR, I bought it in the spring and have only put about 500 miles on it so I didn't notice that it was in bad shape(the bolt). The hex flats are rounded out. I know, I should have done it right away and found out then; well I didn't so I need some suggestions. HELP!!!!

You can try a big flat tipped screw driver or a bigger alan head, if that has already been exhausted a drill and an easy out may work. Good luck

Hmm...I wonder if one of those new extractor-type socket thingies would work. Worth a try - you can buy them at Sears.

mine is not stripped but in so tight that i have never (i've owned the bike for 8 years) been able to remove it. i drain my oil thru the oil filter outlet and then the mesh screen filter on the side. i have a rear wheel stand and once it quits leaking from these 2 orifices i tilt the bike while on the stand to the right side and the rest pours out. not the smoothest operation but since i only ride a few thousand a year it has not been a big deal.
another option would be to warm the bike up good and try the methods mentioned by the others above. maybe the heat will help things expand and you'll get lucky. and spin it out.
good luck!

if you have any torx bits, take the one that's barely too large to fit in the rounded out hole. persuade it into the hole with a hammer (don't wack it TOO hard... remember the cases are aluminum as is the thread the plug goes into)... once the torx bit is seated well into the bolt, try to unthread as normal. the torx bit should have a good "grip" in the hole and the impacts required to drive it into the damaged plug should help unseize it.
then... get an aftermarket replacement plug.

Sticky, don't sweat it. They are crap from the factory but are easy enough to get out even when stripped. Each time I changed the oil I remember thinking I should do something about the crappy drain plug put never did until finally it stripped. All I did is put a little grease on a 14mm (IIRC) allen and roll it in some sand. Gripped just fine. Make sure you have a bar or long handled ratchet and that the socket is absolutely level. Failing all this, at least you are mobile and can take it to a shop for help Fortunately the aftermarket ones work well.

I use valve lapping compound to do the same thing.

When it gets installed folks need to remember it is not holding the whole bike together!

Great stuff guy, I'm a new Duc owner, and will be doing most of the servicing myself. Although the wife insist I have the first service done by the dealer.

Large Channel-locks or vice grips will work as well, grip it around the edge and have at it!

Wow, neat ideas - especially the one about grease and sand on an allen key - never heard that before. Cool.

Thanks for all the replies peeps, I'm going to try the Torx driver method(after I get a replacement). I'll post up after and let you know how it goes.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by NC Rick &raquo;</TD></TR><TR><TD CLASS="quote">
When it gets installed folks need to remember it is not holding the whole bike together!</TD></TR></TABLE>

Very good point!! People seem to wanna wrench down on those buggers...

Hey Mike, does your oil drain bolt take the allen wrench or the socket end? My 95 has the 21mm socket end, never any issues taking it off. I wonder if you got yours off, could you change it over to socket? Have you tried an impact wrench to break it loose? At least you got a good way to drain it after all. I don't like those allen type drain bolts, cuz when you round a flat spot, you know you're in trouble. 40-44 Nm is the spec.

Well the replacement should be delivered today and I've been checking my options. There isn't a torx(that I've found) big enough nor an EZ-Out. I could use an EZ-out by drilling it but I'm afraid of what I might hit inside the oil pan, I'm contemplateing chopping an ez-out down to reduce it's overall length..


suggestions? Should I try the grease and sand method?

I would try the grease and sand method first, it's the easiest, cheapest, and not destructive.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Capt. Home Slice &raquo;</TD></TR><TR><TD CLASS="quote">Large Channel-locks or vice grips will work as well, grip it around the edge and have at it!</TD></TR></TABLE>

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Dutch900 &raquo;</TD></TR><TR><TD CLASS="quote">I would try the grease and sand method first, it's the easiest, cheapest, and not destructive.</TD></TR></TABLE>

i like the sound of this idea too. obviously vice grips and channel locks wont work on the allen head, flush mounted plug.

[Sticky]

I gave up, took it to the pros. It's done, my wallet will feel lighter.