squidygasgas Posted November 22, 2010 Report Share Posted November 22, 2010 Hi everyone! Im new to this forum, and couldnt manage to find anything to help me on this topic! Was planning on changing oil this morning and sump bolt snapped so how do i got about getting the rest of it out? Drilling im guessing? and also where can i get a replacement sump bolt from? Its a gas gas txt 200 2004! thanks for your help in advance Quote Link to comment Share on other sites More sharing options...
roester Posted November 22, 2010 Report Share Posted November 22, 2010 I snapped the head off a sump bolt a couple of years ago when trying to undo it and was gutted! However, I actually managed to get it out quite easily. I bought an Easy Out set which are spiral shaped bolt extractors - probably loads available on eBay. I then centre punched right in the middle of the bolt stub and carefully drilled in about a centimeter. I then screwed in the Easy Out anti-clockwise and it threaded the sheared off bolt out almost as easily as if I was using a spanner. I was worried about getting metal swarf into the bottom of the engine so I bought a replacement sump bolt first, measured it and made sure that I didn't drill all of the way through - the bolt for my bike, a Yamaha, was solid right the way through - if there is a magnet in the Gas Gas one it might be different. You could get a replacement bolt from any Gas Gas dealer, straight from the importers or probably from eBay. Good luck - Alan Quote Link to comment Share on other sites More sharing options...
pete_scorpa3 Posted November 22, 2010 Report Share Posted November 22, 2010 Hi everyone! Im new to this forum, and couldnt manage to find anything to help me on this topic! Was planning on changing oil this morning and sump bolt snapped so how do i got about getting the rest of it out? Drilling im guessing? and also where can i get a replacement sump bolt from? Its a gas gas txt 200 2004! thanks for your help in advance Give BVM Moto at Stroud a call, you'll probably get the new plug through the post within 24 hours. Quote Link to comment Share on other sites More sharing options...
squidygasgas Posted November 22, 2010 Author Report Share Posted November 22, 2010 Cheers for the help! Just ordered a new sump plug! Was thinking mayby when I drill it out could I put a left handed tap into it! Then get a left handed bolt and screw into it? Then should be able to get it out? Quote Link to comment Share on other sites More sharing options...
1oldbanjo Posted November 22, 2010 Report Share Posted November 22, 2010 (edited) Why did it shear off? Are the threads corroded or stuck, was it too tight, was the head damaged in some way? If the original bolt sheared off - it is not unreasonable to think that a smaller diameter bolt threaded inside the original one will just shear off as well...and left hand taps and hardened left hand bolts are difficult to find. Left hand drills some times work when the bolt head was sheared off from someone trying to tighten it too much - once the head breaks off the stresses are relieved and the threaded portion comes out pretty easily. You can sometimes use a small punch and tap the bolt in a counterclockwise direction until enough sticks out that you can get a grip on it with some pliers. I have also on occasion been able to place a nut over the stud and weld through the nut and get a good enough attachment to the stud that it can be turned out with a wrench. When the threads are corroded or cross threaded so tight that the head breaks off while trying to loosen the original bolt, it can be very hard to get the original bolt to come out. I sometimes have success with the "easy out" approach and the hardened tools sometimes will remove a stuck bolt - but not always (Be very careful not to break off a hardened tool in the bolt - you will have to use a Dremel tool with a small grinding stone to get it out.....and it takes many stones and lots of time to grind it out of the tiny hole). Sometimes I have to very slowly drill the bolt out with successive sizes of drills until most of the original bolt is gone and you can pick the bolt theads out of the grooves with an ice pick.....this is always very risky when you have to go this far to remove a stuck bolt. It is very important that you use a center punch to accurately drill the center of the bolt when you first start drilling. If there are any threads on the case that are visible I sometimes put a bolt of the right size and thread in my lathe and then bore a hole through the center of the bolt with the drill I am going to use - then I can insert the bolt into the case and drill through the bolt and it will automatically center and align the drill. Good Luck! Edited November 22, 2010 by 1oldbanjo Quote Link to comment Share on other sites More sharing options...
squidygasgas Posted November 22, 2010 Author Report Share Posted November 22, 2010 Thanks once again for the reply I have just managed to get it out using a screwdriver, as there was a nice slit in the middle of the plug! So managed to get it off thank god! Should have the new plug tomorrow along with some atf oil thanks again Quote Link to comment Share on other sites More sharing options...
jse Posted November 22, 2010 Report Share Posted November 22, 2010 Thanks once again for the reply I have just managed to get it out using a screwdriver, as there was a nice slit in the middle of the plug! So managed to get it off thank god! Should have the new plug tomorrow along with some atf oil thanks again The lower sump plugs have a magnet in the center so be sure you have that out also. If the magnet has come off the end it would probably adhere to a gear and then you have BIG problems. Jon Quote Link to comment Share on other sites More sharing options...
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