I may be totally off and making a dumb mistake, but I just bought a TXC 250 and am trying to change the oil. I remove the engine guard, gas filler cap, and am trying to remove the drain plug but it's not coming off. I can turn it both clockwise and counter clockwise and it will not tighten or loosen anymore, however, it's loose enough to spin it by finger but I still cannot remove it. Any ideas? Am I missing something?
See if you can get a putty knife or screw driver under the lip of the bolt, apply slight pressure, the rotate counter clockwise to remove. I've no idea what the best way to fix that.
If you can get the plug out there are expanding rubber plugs that work well in holes with stripped threads, if you don't want to try one of the thread insert options. I would also try as Coffee suggested. I think I would try tapping on a putty knife on each side while trying to get the threads to engage. Got a helper?
I've been trying for awhile now with the putty knife but I cannot seem to get the threads to engage. If anything, it seems like I may have stripped it even more. Just wanted a quick oil change to get ready for my ride this weekend, but looks like I just got myself into a big problem. Any tips would be greatly appreciated.
I guess getting it out is problem #1 ....after that it can re-tapped in some manner or the rubber plug treatment .... Maybe lay the bike over and use a hack-saw blade to cut the head off the plug .... I'm not 100% where that will leave you if successful as the rest of the plug might try to fall back inside the engine and you do not want that for sure .... OR maybe a putty knife on 2 sides and just pry it out BUT don't bust the cases... This is delicate work ... maybe put the crowds' all time favorite tool, vice grips, on the plug and pull straight down on the plug while turning the plug .... Some one else here probably has dealt with this before maybe and will have a end to end solution .....
I'm not familiar with the TXC250 design, but is it possible to lay the bike on it's side and remove the clutch cover to see if the oil drain plug is exposed (enters the engine case). If so, you could apply pressure to the end of the drain plug (from the inside) while attempting to unscrew it.
If what you are doing 'feels' wrong, stop. Taking it to someone might be a good option. Does not need to be a Motorcycle place, it is amazing the amount of help you could get at an autoparts store for instance - they seem to like challenges instead of waiting for customers behind the counter.
Yep and remember ... those cases are cast or what ever and weaker than the plug... meaning you can snap a big hole in the case if not careful ... Also, the engine oil can be drained from either of the 2 oil screens on the left side of the motor for future reference ...
Try taking the oil filter [screen] out closest to the drain plug & put pressure from the inside. Be carefull!
Hey Guys, I finally got it out. A mechanic helped me out and with a little more skill and a helper, he was able to get it out with a puddy knife while unscrewing. The bolt was stripped bad so we cleaned it out a bit. The threads on the case were in OK shape so he used a thread chaser to clean it up. Need to order new bolts now Planning to buy drain bolts from 7602. I'm thinking the bottom drain bolt will be weak now since I've used the thread chaser on it. I can drain oil from the oil screen, but won't it be difficult to completely drain it since it's not directly on the bottom?
Sounds great! The threads were really ok and the actual bolt was messed up? What year bike? That sounds like a really good idea.
you can tip the bike after removing the filter screws and get the oil out from there if you need to. new stuff sounds better though.
The threads in the case were OK, but needed to be chased down a bit. The bolt was dunzo. The mechanic recommended getting this bolt for the screen and draining it from there whenever I do my oil changes from now on. Is this normal? I notice 7602 also has a draining bolt for the window/screen for KTMs. What advantages come from draining through the window (side) vs the regular drain bolt (bottom)?
That sounds like a great question for the 7602 merchant forum http://www.cafehusky.com/forums/7602-racing.33/
Good new there for sure on the cases .... maybe that plug is aluminum so that the cases are harder material and will not strip out ... I'd get something new for sure to plug that drain... That very front small screen plug actually drains out about a 1/2 cup more oil after the drain plug runs dry if you tip the bike over some on the side ... Not sure what it does if the plug is not removed first and allowed to drain .... I always drain both and just use the sight glass to refill the engine....
Here is a pic of the other 2 oil screen locations in question ... Some have known to have stripped that front allen head so be careful there also ... The drain plug is in the background also ... PS -- I either gotta wash my bike or ride it today ...
