TW200 Forum banner

1 - 20 of 22 Posts

·
Registered
Joined
·
18 Posts
Discussion Starter #1
Help, my drain plug seems to have seized and won't budge. You can see how its stripped from my attemps. I am using a standard wrench and the size is correct, it just seems like it's fused in. The bike is an '09 model and I bought it used, it has about 40k miles and I have never changed its oil. Any ideas on how to loosen that sucker?







many thanks
 

·
Registered
Joined
·
269 Posts
I'm sure someone who had dealt with this will come on and give you some advice.



If it were me, and in the absence of any better ideas, I'd get a new plug, then use a dremel to cut a deep slot in the head. Then I would put the bike against a wall so I could push hard against it. I would use a small prybar or similar that fit the slot nice and tight, push hard and turn.



Hopefully someone will have a much better and proven idea for you!
 

·
Registered
Joined
·
2,126 Posts
Was overtightened by last person who changed oil. It only has to be snugged down, not cranked down by someone worried it will fall out. pound a tight fitting 6 point socket on and try that. If that doesn't work then chisel on very outside of plug but be careful and don't damage case. Of course have new plug (with o ring)on hand because won't want to use old chewed up plug.
 

·
Registered
Joined
·
2,126 Posts
forgot to say that you would want to chisel on bottom toward back of bike so force would be turning stuck plug counter clockwise.
 

·
Registered
Joined
·
1,619 Posts
I lost track of all the stuck drain plug threads



http://tw200forum.co...ug-rounded-off/



http://tw200forum.co...ain-plug-stuck/



http://tw200forum.co...ped-drain-plug/



http://tw200forum.co...1/ShowPost.aspx



http://tw200forum.co...8/ShowPost.aspx



http://tw200forum.co...2/ShowPost.aspx







From an old post by Jimbo





The torque Specs for The drain plug and filter covers is as follows.

Big Drain plug=(43Nm or 31 ft/lbs.)

Screw oil filter cover-upper=(7Nm or 5.1ft/lbs.)

Bolt oil filter cover-lower=(10Nm or7.2ft/lbs.)
 

·
Registered
Joined
·
1,302 Posts
I'm gonna quote myself from another thread. This is most definitely the safest way I've done it so far.



If you can't get a grab on it with anything, the socket and JB Weld trick does wonders, and you can even keep the plug as a spare or leave it on for easy removal.


Just get an 18mm/19mm 6-point socket (something snug, flush, and shallow) and put a piece of paper or something in the bottom to separate the drive side and the socket side. Mix up your JB in the socket, fit to drain bolt, wipe excess, and wait a day. 1/2" drive socket would be best.
 

·
Registered
Joined
·
269 Posts
I'm gonna quote myself from another thread. This is most definitely the safest way I've done it so far.







Just get an 18mm/19mm 6-point socket (something snug, flush, and shallow) and put a piece of paper or something in the bottom to separate the drive side and the socket side. Mix up your JB in the socket, fit to drain bolt, wipe excess, and wait a day. 1/2" drive socket would be best.




See, I told you someone would come along with a better way!
 

·
Registered
Joined
·
184 Posts
If the jb weld doesn't work, try grabbing the outer edge of the plug with some needle nose pliers). Or, very carefully use a hammer and flat head screwdriver to try and tap it loose. Tap the outer edge of the plug, not the bolt head. Once you get a little groove in the plug, it should start to move, or just break. Either way, have a new plug ready. Yours needs to be replaced.



My old cr250 used a very similar plug for the exhaust valve check cover. PO tightened it too much and I used a screwdriver and hammer to carefully tap the outer edges (making sure to go easy and not touch/gouge the engine) and the plug eventually cracked and came right off.



This was pre-plug replacement. The chipped bolt head corners should have clued me in...haha



 

·
Registered
Joined
·
18 Posts
Discussion Starter #9
Thanks everyone, I was afraid it was going to get destructive.. will have to order a new plug before I try the above. Any ideas where I can find one online?



thanks
 

·
Registered
Joined
·
1,302 Posts
I think Stadium Yamaha or Boats.net are the reliable ones for price and keeping full stock. I used Bikebandit once and got dragged around for a week on backorder and billing issues.
 

·
Banned
Joined
·
10,664 Posts
Make sure to verify the total price (part + shipping and handling) so you don't have any nasty surprises.



I used a dremel to carefully reshape a similar plug to take a 17mm 6-point socket and used a hand impact to loosen the plug. Far as I know, the modified plug is still in use, though these days the owner uses a torque wrench for installation.
 

·
Registered
Joined
·
9 Posts
I had the same problem with stuck drain plug on my 2013 TW. I used a small center punch along the outside edge of the plug and tapped lightly. The impact from the tapping worked. From here on out I will use a 1/2" drive torque wrench set at 31 foot lbs. as not to overtighten in the future.
 

·
Registered
Joined
·
93 Posts
I had same the issue in the past, and solved it very quickly by using a nail set. Hit it till it bites, then angle the nail set and hammer it free!
 

·
Registered
Joined
·
67 Posts
2nd oil change today since getting the bike and nearly rounded the plug. Too much cussing and fussing for a simple job! 19mm box end with another wrench as a guide to keep the torque exactly perpendicular to the bolt while any of three fingers was waiting for the smash. Swapped a more hexagonal plug in from the parts bike. (Yay, bike carcass!) May go with JB weld+socket from here on out.
 

·
Registered
Joined
·
261 Posts
I'm gonna quote myself from another thread. This is most definitely the safest way I've done it so far.






Just get an 18mm/19mm 6-point socket (something snug, flush, and shallow) and put a piece of paper or something in the bottom to separate the drive side and the socket side. Mix up your JB in the socket, fit to drain bolt, wipe excess, and wait a day. 1/2" drive socket would be best.
Does anyone have a picture of what this JB Weld / Socket looks like? I understand better with pictures.
 

·
Registered
Joined
·
19,580 Posts
When Admiral did his engine swap here his plug was rounded off and we had similar difficulty extracting it. Once removed I put in in my vise and quickly filed that 19mm down to something about 18mm across the flats just to move forward so we could fill motor with fresh oil and go for a test spin.
Wonder if he has forgiven me yet?
 

·
Registered
Joined
·
19,580 Posts
I'm quite happy with the gal I have.
IMG_1199.jpg
No need for a harem. How those poor martyrs deal with 73 whinny virgins in Paradise is beyond me. "Master, does this burka make my butt look big?"
 

·
Registered
Joined
·
13,402 Posts
When Admiral did his engine swap here his plug was rounded off and we had similar difficulty extracting it. Once removed I put in in my vise and quickly filed that 19mm down to something about 18mm across the flats just to move forward so we could fill motor with fresh oil and go for a test spin.
Wonder if he has forgiven me yet?
Yeah Fred, this mod to 18mm works great. I can use either an 18mm socket or wrench and have not had any issues with it.
You da man!
 

·
Registered
Joined
·
54 Posts
Just wondering if the torque spec is a bit high for hot,warm motor.I changed my oil
5 times this year and just snugged the plug up,the bike was hot and old friend told
me if its hot snug it, cold tighten it my 2 cents
 

·
Registered
Joined
·
3,478 Posts
Yes, the spec assumes, as ALMOST ALL torque specs do, that the parts are at room temperature. So you are correct. However, "snug" is a very subjective term, and given the catastrophic damage loss of the drain plug would cause, I would definitely check the value the next time the bike was cool. I also agree that the 31 ft./lb. spec is a bit high....I use 30, but I'll bet 29 would be fine, too. If you test your "snug" by using a torque wrench to break the plug loose when it's cool and discover that you've really only got 15 ft./lbs, you are asking for trouble. :eek: :eek:

I also have never rounded off my plug because I always use a 6 point 19 mm. socket and a 1/2 inch drive with 18" long ratchet handle. 12 point sockets or box ends are MUCH more likely to cause rounding. :mad:
 
1 - 20 of 22 Posts
Top