Sheared oil bolt in sump. How to get it out? - Kawasaki KLR 650 Forum
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post #1 of 21 Old 09-09-2012, 12:55 PM Thread Starter
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Sheared oil bolt in sump. How to get it out?

I got some good advice from guys following another thread while this happened. But I want to think through all my options and procedure very carefully before i start taking things apart.

What happened: 1994 KLR. Putting the oil plug bolt back in after draining oil. It's one on the ones with the magnet in it. The bottom half of the bolt is hollow with this magnet in it. As I'm putting it in the bolt bound up on the washer and the extra torque sheared the bolt off where it goes from solid to hollow housing the magnet.

Up until a few hours ago I had not heard of a left hand drill bit. You can see where this is going. I try drilling for an easy out but of course the center of the sheared portion is the magnet and wont drill. Then it catches and threads the remains of the bolt right through into my oil sump.

Now I have a 1/4 piece of bolt and magnet in my oil sump.

What are my options for trying to get it out starting with the least invasive? I really don't want to tear this whole engine apart.
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post #2 of 21 Old 09-09-2012, 02:57 PM
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Quote:
Originally Posted by troutbum33 View Post
I got some good advice from guys following another thread while this happened. But I want to think through all my options and procedure very carefully before i start taking things apart.

What happened: 1994 KLR. Putting the oil plug bolt back in after draining oil. It's one on the ones with the magnet in it. The bottom half of the bolt is hollow with this magnet in it. As I'm putting it in the bolt bound up on the washer and the extra torque sheared the bolt off where it goes from solid to hollow housing the magnet.

Up until a few hours ago I had not heard of a left hand drill bit. You can see where this is going. I try drilling for an easy out but of course the center of the sheared portion is the magnet and wont drill. Then it catches and threads the remains of the bolt right through into my oil sump.

Now I have a 1/4 piece of bolt and magnet in my oil sump.

What are my options for trying to get it out starting with the least invasive? I really don't want to tear this whole engine apart.


The bolt broke in half across the threads? The piece inside is the full diameter?

If so can you see it? Tried to fish around with a magnet or tweezers or something ? If you could get it lined back up with the hole maybe you could get it started in the threads?

Tough situation for sure. I don't know if the oil screen hole is big enough to fit the bolt through. The only other hole into the transmission I can think of would be the shift shaft.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #3 of 21 Old 09-09-2012, 04:02 PM Thread Starter
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I think I'm liable to make thinks worse if I start tearing it apart. First bike, never opened up a KLR.

Anyone in Boise Idaho with experience willing to help?
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post #4 of 21 Old 09-09-2012, 04:04 PM Thread Starter
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Originally Posted by Spec View Post
The bolt broke in half across the threads? The piece inside is the full diameter?

If so can you see it? Tried to fish around with a magnet or tweezers or something ? If you could get it lined back up with the hole maybe you could get it started in the threads?

Tough situation for sure. I don't know if the oil screen hole is big enough to fit the bolt through. The only other hole into the transmission I can think of would be the shift shaft.
Full Diameter. No chance of getting it lined back up I dont think, and then getting pressure and turns on it.
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post #5 of 21 Old 09-09-2012, 04:20 PM
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Hmmm...? Time to earn my keep as it were...lol

OK, are you saying that you can get a drill through the magnet at the moment or have not yet taken it to this level yet? If you have I would be very carefull as to where this magnet wants to stick itself to. It will go straight towards the nearest hunk of metal and that would be your transmission I think, not a good thing IMHO. If you have already drilled through the magnet and it's still in the oil plug I would sticka strongish wire through the hole you have made so you can't loose the magnet like above. If you have lost it already I would be getting the best flashlight you can and shine it up into the transmission and look very carefully for the bits. If you can't find them......I would be taking the left side covers off and all parts to get behind the rotor, starter gear and the DOO idler gear and shaft. That is the biggest hole in which you can fish into that cavity. This where I usually fish for broken DOO parts or spring parts, if not there I go after the oil screen. I never start an engine up without first finding out where all parts are or if I haven't found them after an hour or two of fishing. I would then turn the engine over by hand and go through all gears hoping not to feel a stoppage due to a piece of foriegn material. This where you are now I think or soon will be. Can you post up pics of this mess and also pics of what is left of the plug. Perhaps we can count how many threads are still inside the case and work to figure out how best to get them out without loosing the magnet. Once it attaches to a larger object with a greater pull it will be very hard to get it off without some magical help I'm afraid. I would try and make up a piece of plastic or wood that wouldn't snap off deep inside your engine, preferably plastic, thin is good like a cigarette package thickness....Just something to stop that magnet being able to attach itself to something important. I hope this is as clear as I see it in my head. It's starting to sound muddy....sorry. If you can do this then drilling through the magnet is possible maybe. Even a light tap with a small punch to dislodge the magnet from the plug if all else fails. I think I would try to find a way to tap it back out using a very small punch and a small hammer. You may damage the threads of the case but you can always repair those using a heli coil.
What about using a larger drill and removing enough material on the outwardly side of the magnet so it is retrievable from the outside using a stronger magnet...? Then go in and clean up what is left of the threads. The new larger drill bit shouldn't be that much bigger than the inside diameter of the threads I wouldn't think. It may then just be a retapping to get the threads back to new in the same size.

Hope some part of this is helpfull. Just go slow and think each move through and what conciquences each move brings before doing it.


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post #6 of 21 Old 09-09-2012, 04:32 PM
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Augh....now I see.....it's already inside the engine or transmission section.......damn man!
Now you need to take off the left side covers and remover the rotor, starter gear and idler gear for the DOO chain. From here you should be able to fish to where the parts are hiding. IF you are extremely lucky it hasn't already stuck itself to some other metal part deep inside. I would be looking as best you can using a good flashlight and see if you can see it, if you can, bad news! It would mean it's already attached itself to something IMHO or it would be still on the sump pan....which could be the case.....keep your fingers crossed! I'd cross my toes too if it were me! If this is the case, I would now carefully fish with a bendable magnet on a copper or brass pipe. It can be bent into the shape needed to get all the way deep to the sump location, it may just attract the other magnet and bob's your uncle and you are a winner! Go buy a lottery ticket asap! If not and it's stuck on a transmission gear......you have to be able to see and guide something to try and knock it off and drop it into the sump if you can.
If that isn't possible......I'm afraid it will be possibly case splitting time.....sorry.
BUT...make sure you look first and act later......the after effects of doing it wrong are huge and expensive!:scream:

If it hasn't already attached itself to something it only needs to find a metal object to jump to, so a metal rod bend would work I think over the magnet, just have to pray it doesn't push it to a larger hunk of metal with more pulling power before it sticks to your rod.....oh that doesn't sound right.....lol

Willys

Last edited by willys; 09-09-2012 at 04:34 PM.
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post #7 of 21 Old 09-09-2012, 09:35 PM
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Wow, damn. Rare earth magnets are hella strong. God speed.




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post #8 of 21 Old 09-09-2012, 09:57 PM
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A fresh idea, look first, if you can see it....buy a good set of surgical forcepts and see IF you can clamp them onto it....they have enough clamping power and may be thin enough to get into the oil drain hole.

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post #9 of 21 Old 09-10-2012, 12:33 AM
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As I understand the problem, the plug fragment rests TOTALLY INSIDE THE SUMP.

None of the suggestions so far offer any possibility of evacuation and removal, as far as I can visualize.

Either 1) Split cases and remove, or

2) Overbore oil drain hole to a diameter large enough to permit removal of plug fragment. Then, tap larger hole for larger plug (perhaps, "piggy-back" drain plug).

Here's an image of a piggy-back plug; before exclaiming over the projection, hex heads could be ground down to reduce projection, even perhaps the inner plug could be replaced with a hex socket machine screw to eliminate any projection at all from the inner plug:



I'd be inclined to try the latter technique (bore oversize, remove plug fragment, tap hole for larger plug).

If a larger plug is impractical, I'd then have the crankcase built up with weld metal, drill, and re-tap for a standard size plug.

Then, if the plug again broke off in the threads, I'd consider obtaining a left-hand twist drill bit to assist in removal!
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post #10 of 21 Old 09-10-2012, 07:13 AM
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Any issue with him just leaving it in there? I wonder if its heavy enough and magnetic that it won't go cause damage anywhere?

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