Yikes! Heeeellpppp (oil drain plug broke off!)
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Thread: Yikes! Heeeellpppp (oil drain plug broke off!)

  1. #1
    Senior Member Soulprogression108's Avatar
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    Yikes! Heeeellpppp (oil drain plug broke off!)

    So ya talk about an oil change gone south. Good news is the old oil is out. Bad news is.... any new oil is coming right on out too!

    The drain plug bolt end sheared off leaving a finger sized hole and me wondering how the [email protected]$& to get the rest of it out now?

    Maybe I can notch into it with a grinder and tap it out with a big flathead?

    Are these things are pretty universal and can I pick one up at a local shop or do I need to overnight?

    Pics for proof of the fun 😵

  2. #2
    Senior Member TW-Brian's Avatar
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    I would try driving a big flat head screwdriver into the hole to see if you can get it to bite and then put a wrench or visegrip on the screwdriver handle and see if you can get it to break loose. Others have used a chisel or screwdriver on the outer edge of the plug to get it moving.

    My guess is that your only source might be Yamaha?

    Best of luck!

  3. #3
    Senior Member nihil's Avatar
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    I'd whack it with a hammer a few times to shock loose whatever kept it sticking, then maybe dremel a groove somewhere convenient along the circumference where I could wedge a screwdriver to whack that with a hammer to start it turning. After it's free some vise grips or channel locks might be enough to back it the rest of the way out.

    As for where to source a replacement, either your local Yamaha dealer or...


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  5. #4
    Senior Member reddave's Avatar
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    I hate to like the Fast and Furious meme, nihil...but I had to!
    nihil and Soulprogression108 like this.
    1987 Yamaha TW200

  6. #5
    Senior Member Soulprogression108's Avatar
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    The fat screwdriver did the trick. I think it broke loose when it BROKE because I barely turned it and just stuck it in by hand and it came right out.

    Well she’s down for now but she’ll be back!
    Errtu, TW-Brian, grewen and 2 others like this.

  7. #6
    Member kangaroo's Avatar
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    There’s a good chance the corrosion has fused the drain bolt to the engine case. Any whacking may cause some other weakened area to crack before breaking the stuck thread. Safer and less metal will get introduced inside by drilling ever increasingly larger holes. Until the last bit can be nudged off. You can also get a stone bit to grind/seemed away in a similar manner.
    Soulprogression108 likes this.
    2006 Tw200

  8. #7
    Senior Member RockyTFS's Avatar
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    When you put the new one in, replace the O-ring if it is over five years old and use 28 ft/lbs. torque instead of 31.
    Rocky
    2018 TW200
    2014 BMW R1200GS LC

  9. #8
    Senior Member Gastone165's Avatar
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    In the past I’ve heated the broken bolt etc with a torch to as high a temperature as possible without damaging anything nearby, and then I take a can of compressed air, turn it upside down, and spray the fluid on the just the bolt to cool it as rapidly as possible. This process repeated a few times may be enough to loosen the bond between the broken bolt and the surrounding threads. The heat can possibly boil some penetrating oil into the threads as well.
    It works quite often. And if it doesn’t, you still have all the more drastic options available.
    1972 Yamaha DT 175, 1974 Kawasaki 125, 1976 Suzuki TM 250, 1979 Yamaha 750, 1977 Husquvarna 360, 1979 Husquvarna 250, (2) 1980 Suzuki RM 400’s, 1971 Husquvarna 400, 1983 Honda V65 Magna, 1987 Suzuki 230 Quad, 1987 TW200, 1990 TW200, 1996 Honda XR 650, 1998 Yamaha 300 King Quad, 2000 Harley Davidson Heritage, 2006 Kawasaki KLX 250s, 2007 Arctic Cat 650 Quad, 2010 Polaris Sportsman 850 Quad, 2006 Yamaha Grizzly 660 Quad, 2002 TW200, 1995 TW200, 2008 TW200, 2016 TW200.

  10. #9
    Senior Member Soulprogression108's Avatar
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    Thank you everyone for the help. I got it free and now await an order from boats.net

  11. #10
    Senior Member elime's Avatar
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    Just so you will know you are not alone the same thing happened to me. At 8 o'clock you can see where my chisel cut into the aluminum so I could loosen and unscrew it. I screwed it back into a spare case I have so I could take the picture.
    PB020032.JPG
    Long live the internal combustion engine!

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