Hey everybody, I need some help. I recently bought a 96 yz 250, and I have only taken it out 2 times. I decided it's time to change the oil, but when I looked under there the drain bolt was slightly stripped already. When I tried, I stripped it worse. I've been spraying pb blaster on it for 2 days now, and I tried vice grips this morning. The bolt is completely mangled by this point so I went to sears to buy damaged bolt extractors, and had no luck. I'm afraid to hammer on the extractor more because I don't want to damage the pans threads. ANY IDEAS!?

 

Can you get a dremel in there? If so, get a cutting disc, make a slot for a screwdriver (make sure to use a large one though) and try that method. If you need more leverage, you can put a wrench on the screwdriver's handle.

 

yeah there is room for a dremel. do you really think I can get it loose with a screwdriver though? I couldn't get it to budge when I had a box wrench on it.

 

I have the craftsman bolt extractors from sears. I used them to do exactly what you want to do. I did have to tap the extractor on with a hammer. Just enough to get it to bite so it would dig in when you wrench on it. No damage to the extractor. Once you have it on there good, use a breaker bar if you still have problems.

 

Heat and patience are going to be your best friend on this one. If you can drill the plug and get an EZ-Out in their and then heat it up with a torch you should be able to get it out.

 

Its hard to tell how big of a bolt head that is but if there is enough room I have had success grinding off two opposite sides flat so I can get a wrench on it. Also I have this tool http://www.endeavorproducts.com/ and it works pretty well on most stripped nuts and bolts.

 

When you get an extractor in a position to get a good bite. Warm the engine up to operating temperature, and them spray the stud down real good with R134A. then try extracting it.

 

If you have a wire feed welder then put a larger nut over the bolt and weld away. then you can use a bigger wrench.

 

yea either grind a spot for a screwdriver or weld a nut on it

 

Lots of good ideas here. any luck?

 

on another note..any pics of the bike?

 

Best idea!

 

I like the wrench idea. Done that on a John Deere 4240 one time. The plug got rounded off so we just ground two sides down to a smaller size wrench. Should work with that round head too, just grind it down till a wrench fits.

 

I agree with the wrench, but even better would be to grind 2 sides flat (and STRAIGHT SIDES) and then clamp a large vice grip on REALLY tight and the smack it hard one blow with about a 3 lb hammer. The JOLT is what will break it loose! (looks like Jiffy Lube tightened that one up!)

 

I've had success using a impact tool like this after you cut a nice deep screwdriver slot.
Using a dead head hammer will also help when using the impact tool.