Maintenance & Technical > KX500 Original

Oil plug problems-

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Dodd:
Made it through 3/4 of the roadracer build on my 91 KX5. Then today I went to drain the transmission and found there is a serious problem-

The plug seems stripped. It turns in the case but doesn't back out. Tried pulling on it while turning and a handfull of other goofy attempts to get it out.

Did a cursory search for solutions but didn't find any. Suggestions?

Thanks,
Dodd

sandblaster:
You might try this thread.
http://www.kxriders.com/forums/index.php/topic,6507.0.html

Dodd:
Thanks for the link- good info. However, how do you get the plug out? lay it on her side and pull with a vice grip, or will this damage the boss beyond repair?

Dodd

sandblaster:
In the past I have used a set of vice grips and did the pull and twist method.
If that does not work, I have also grabbed the head with the Vice Grips and used a block of wood against the case and pried against the wood and the Vice Grips.
When that fails I have used a bearing splitter or I drill it out.
The idea of drilling the plug threads with air blowing in from above is good.
Another thing you can do is put a good amount of grease on the drill bit to help catch the shavings and prevent them getting loose in your case.
After the plug threads have been repaired, I like to flush it out with some ATF or diesel.

Dodd:
Great info. Thanks, and I'll let you know how it turns out-
Dodd

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