Sump plug bolt

[Jimbo_Bimbo]

:oops: sump plug bolt has rounded!

took the oppurtunity to do an oil and filter change on sunday as the rain had stopped. When i tried to undo the sump plug bolt the socket went round but the bolt didnt :(

Dunno why this has happened as i did it up last time to the right torque, unless my torque wrench is knackered too.

My problem is how to get the bolt out, and where can i get a new one from? does it have to be from suzuki?

[hovis]

why on earth would you want to do it up with a torque wrench?

getting it out may be tricky

can you get molegrips on it?

should be cheap enough for a new one

[yorkie_chris]

I would guess it's a suzuki one, it's fine pitch IIRC

Don't do it up so tight next time.

Mole grips, or carefully weld something to the bolt to get it off.

[hovis]

carefully weld something to the bolt to get it off.
is'nt it ally?

[yorkie_chris]

Not unless they make magnetic ally

[sv650k4]

Getting a new one wont be all that dear or hard 2 get your only problem is geting your old one out now.as said above dont tighten it as much the next time! and 2 try and get this one out either go the next socket down and hammer it on if its not rounded enough for that then either weld something 2 it or try mole grips.


;)

[hovis]

Not unless they make magnetic ally


oh........

the one on my bike is alloy, with a magnet fitted to it

[yorkie_chris]

OK then that's worth checking before you put MIG gun on it

[Biker Biggles]

Also whatever you do dont strip the thread in the (alloy) crankcase as that gets expensive to sort out.

[hovis]

OK then that's worth checking before you put MIG gun on it might be differant on the sv?

Also whatever you do dont strip the thread in the (alloy) crankcase as that gets expensive to sort out. is it a steel bolt into alloy casing?

[yorkie_chris]

Yeah kinda goes without saying but make sure you're turning it the right way...

[yorkie_chris]

Definately an alloy casing. If I've got an engine handy I'll have a closer look...

[yorkie_chris]

Nah CBA ... both spare engines are stuck behind RD400 and loads of stuff. Can't be arsd digging.

[hovis]

Definately an alloy casing. If I've got an engine handy I'll have a closer look...
:mrgreen:

i bet you have one in the kitchen;)

[yorkie_chris]

Only when the folks are away

[Jimbo_Bimbo]

Thanks guys.

Have molegrips and welder. Maybe i'll weld the mole grips onto the bolt :)

For future reference...how tight should the simp plug be?

[hovis]

i would do it hand tight......... then just a bit more, kind of just to pinch it up.

[Dangerous Dave]

i would do it hand tight......... then just a bit more, kind of just to pinch it up.
Correct, there should be a washer on the bolt which makes the seal.

[andyharding]

Is it an hex head or a cap head sump plug. MIne is a cap head so if it is the same i would get a slightly bigger allen key (probably will be an imperial one) and just tap it in. This will make the plug loose and give you a better grip in the cap head.

[sibbo]

before you go at it with the welder a word of warning disconnect yer battery and rectifier multip[lug as you could end up damaging yer alternator and frying yer battery.... you could try drilling a small hole in it and use a screw extractor its like a tap only works other way round apply a little bit of heat to the caseing around the bolt then with the help of a mate use both mole grips and extractor together when you eventually get it out put a new washer/copper o'ring on every time and dont over tighten it a short spanner should be enough
good luck if you strip the thread drop me a line i may be able to helicoil it for you?

[yorkie_chris]

It's a normal hex head, there is another drain hole under the oil pump pickup which uses an 8mm(iirc) socket (allen key) type bolt.

You could also try tap on a double hex socket of a slightly smaller size, or even a torx socket.

[Jimbo_Bimbo]

before you go at it with the welder a word of warning disconnect yer battery and rectifier multip[lug as you could end up damaging yer alternator and frying yer battery.... you could try drilling a small hole in it and use a screw extractor its like a tap only works other way round apply a little bit of heat to the caseing around the bolt then with the help of a mate use both mole grips and extractor together when you eventually get it out put a new washer/copper o'ring on every time and dont over tighten it a short spanner should be enough
good luck if you strip the thread drop me a line i may be able to helicoil it for you?

Thanks for the tips.

I'll try mole grips and then screw extractor. Failing that i may even try and drill it out without damaging the case.

[Biker Biggles]

If its that hard to get out it might be worth taking the bike to somewhere with the right equipement to get it out and possibly repair the thread damage that you may find.This while the bike is still usable which it wont be with the bolt out and a stripped thread.

[the_lone_wolf]

the bolts on the KTM engines are notorious for seizing up and being pigs to remove

recommended aid is to put a bit of copper grease on the threads when you do the bolt back up, can't see any reason why it wouldn't apply equally well to the SV

[sweepdoggydog]

I have removed rounded bolts by hammering a socket one size smaller onto the rounded bolt. This usually gets them off without too much hassle.

[fastdruid]

why on earth would you want to do it up with a torque wrench?


So that it doesn't fall out and you don't crack the sump?

WRG to the original question, there are a couple of things to try, you can get special sockets that cut into the bolt to grip it (like http://news.thomasnet.com/fullstory/475371 ) or you can try hammering on a smaller socket (imperial work well for this).
Worst case you can get someone to weld another bolt onto it[1].

Druid

[1] Disconnect the clocks, ecu, reg/rec and battery first!

[hovis]

So that it doesn't fall out and you don't crack the sump?

!
lol


just use a bit of commen sense when doing it up

[Jimbo_Bimbo]

Righto. Got mole grips, welder, various sockets, bolt extractor, hammer and i may even have a look for a bolt extractor socket.

Will tackle it this weekend, and then replace with new bolt and washer and only tighten it enough :)

[fastdruid]

Righto. Got mole grips, welder, various sockets, bolt extractor, hammer and i may even have a look for a bolt extractor socket.

Will tackle it this weekend, and then replace with new bolt and washer and only tighten it enough :)

I've never had a sump bolt round on me but I always use the correct socket and always torque it up to the correct setting.

If the bolt is rounding off you're doing something wrong rather than you are tightening it too much.

Druid