Working on doing an oil change yesterday. The level plug for the drive shaft has become very rusted. So after changing the motor oil and filter i went to remove the level plug and as i feared it stripped out.
#1 in the picture from the manual in case your unclear.
I do have counter thread removal tools, but they require drilling a hole in the bolt first. Not something i care to do if i can avoid it. Would probably want to take the whole back end off so nothing ends up in the drive shaft. Will need to order a replacement plug so have some time to consider how i want to proceed. I have thought maybe i could not drill all the way through and still have enough of a hole to get things going. but i worry about accidently drilling too deep or something else careless. Plus, it might not work and then i might be down a route i can't get out of easily.
Any thoughts on how to get the plug out with minimal pain.
If you care to email me with your phone number, I will talk you thru it.
Yes, but we all want to know . . .
Kel GRiSO Capo
Posts : 88 Join date : 2017-12-09
Subject: Re: Driveshaft level plug issue Sun Jul 07, 2024 4:54 am
In the event the torx method offered by Danmag doesn't work, we would try punches and hammers, with possibly heat and penetrant. This may sound crude however there are correct sizes and applications of these tools. Looking to achieve plug removal with minimal damage with no swarf entering the lube area.
Kel, it's funny you mention using such crude, but effective, methods. A couple evenings ago, I removed some stripped screws from the rear hub of a Yamaha Super Tenere for a guy on the Alaska Highway, using a hammer/chisel. He was returning from a trip to the Arctic Ocean, and had bearing issues, 200 miles from the nearest motorcycle shop.
Just use a light touch, and barely enough force. Oh, and hold your tongue just so.....
Subject: Driveshaft level plug issue 
Fri Jul 05, 2024 2:42 pm
