Tranny Filler Plug

Rick

Rick

New member
Ok....after 10 years of ownership and more oil changes I can count, I have a big problem. My tranny filler plug is tight.....really tight and the hex head is pretty loose....on the verge of stripping.

What is my next move? Do I go for it?? Strip out the hex head?

Do I remove the carb, clutch slave and get out a little propane tourch and give it a little heat?

Do I drill it out, and fill the tranny with shavings? That is not where I want to go just yet.

Ohhhhh, yea, forgot to mention, I need my bike ready by next weekend, as it is being transported down to San Felipe, Mexico for some Baja riding....

Thanks
 
Take a Torx bit that will fit tight in the fill plug.
Tap it into the fill plug, now remove it.
 
If these don't work I would try to grind a slot in the head of the bolt and use a screwdriver. Seems like the heat would expand the alum. before it expanded the cases, might make things worse. Maybe try dry ice on the bolt?
 
Try the Torx trick, if it strips, try walking it out with a chisel. Once out, use an o-ring on the new plug instead of the crush washer so all you have to do is snug it down.
 
If you strip it out leave it alone until you get back from baja. The oil will work just fine and you won't have to worry about anything going into the tranny and making itself known somewhere in baja. Ilike the torx approach, then try walking it outwith the chiesel .... good luck!!!
 
Some more approaches for you:1) First heat up the plug with a torch but don't try to turn it. Let it cool and then heat up the cases around the plug then try to remove it with the Torx bit while the caes are hot. Heating up the plug first will hopefully expand it a bit relative to the hole and hopefully move the case intereference area. Then when you are ready to unthread the plug if you heat up the area around it and not the plug it should loosen it up a little more. 2) If you strip the allen hole there are some different types of easy outs to try. 3) Last but not least you can TIG the plug through a hole on a bar. Quite often TIG welding a bar to a plug will expand the plug even more than a torch and loosens things up a lot (once it cools) and then gives you lots of leverage with a bar to get it out.

Good luck
 
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stuck bolts:hit the head vertically with a big punch to free the threads. if that doesn't free it up, i cut a small slot on the edge of the head with a sharp chisel, then use chisel/hammer in the slot and hit it perpendicular to the head to get it turn a tiny bit. you only need to get it to turn maybe 1/8 of a rotation to free 'em up.....hard to describe in words, but it works every time. haven't used an impact driver in years.. the chisel method is faster and easier....
 
WOW!!! I had problem.....was in serious state of panic.....the Gas Gas community came to help!!!! Thanks for all the ideas. You guys are the BOMB!!

gasgasman nailed it, used a TORX, drove it in with a ball peen hammer, it bottomed out, put a 3/8's breaker bar....out it came!!!

Ok, now to keep it from happening again. I think Glenn said, ditch the brass washer??? Opt for an "o"ring?? Sounds like a plan. I have never, ever had this happen, OEM fill plug.....

Ok, anyone know of a replacement fill plug?

I will be on the hook w/ GoFasters in the morning....

Thanks for all the GREAT idea's.....what a great bunch of guys!!!

Thanks

Rick
 
Yes, ditch the washer. I have always used o-rings on both the fill and drain and snugged them down with two fingers using an allen key. Never a problem in 10 yrs on 3 GGs. Size is not even that important, I'll check what I have but you can start with a 12 x 1.5 thats used on the brake pedal pivot.
 
Thanks Rick, for bringing this up. I just got done changing my oil, and had to use the Torx trick on both plugs. And I'll be calling for some new plugs too. I was able to reinstall the worn plugs properly with the torx bit btw. I'll get a handful of the orings too.
Also, what type of funnel are U guys using? I didn't have a small enough one for the small fill hole. I used some tin foil and the smallest funnel I had.
 
I used to have a small yellow funnel that was used to fill a coleman gas camp stove. It came with a coleman stove my dad got back in the early seventies!! It worked perfect. I would lean the bike against the work bench a bit for a better angle then pop the funnel into the hole. the funnel was just big enough that it could be forced/snapped under one of the clamps on the gas line to the carb. this would hold it nice and tight to the fill hole. worked pissa!!! .... but i haven't been able to find the funnel lately :( ..... now I use a piece of manila file folder cut to size and rolled up into the shape of a funnel and taped to keep it from unrolling. I found that a pop top from a bottle of dawn would screw over an oil bottle I had I then put clear tube over the pop top and you could use that to inject oil into the hole. the componets did not fit that great so it could get a bit messy some times. plus it was kind of slow as you had to let air get back into the bottle. I have some commercial gear oil bottles that came from the local auto parts store. they are roundand hold abot a quart. the come with a neat cut to size squirt top thing ... again perfect for injecting into the hole. I'd use it in the tranny just to use up the oil but I don;t know if it has friction modifiers so I use the stuff on my chain. If I ever empty the damn bottle I might give that a try. You could use it to fashion a funnel of sorts ... The injection method should be nice and clean and fast but to date the camp stove funnel was the best and fastest ...

here you go .... mine was yellow and had no filter screen. I would pull hte screen as I think it would slow down the oil

http://www.campingcomfortably.com/coleman-fuel-funnel.html
 
flybars said:
What type of funnel are U guys using? I didn't have a small enough one for the small fill hole. I used some tin foil and the smallest funnel I had.
Click to expand...
Best thing I've found is those 85w, quart size, transmission oil bottles that have a fill tip made into the cap that looks like the tip of a tube of caulk. You can find them at any auto parts store or bike shop that sells Honda oils.
Just fill the bottle with your regular funnel and then squirt it into your gasser - the small tip will fit right into the fill hole.
 
I use an empty caulk tube. Clean it out really well before using.

Make sure the tip will fit into the oil fill hole.
 
I use an old shampoo pump. I put a pressed on small nose, about 6 inches long onto the pump nozzle. I maked the bottle with a sharpie to the fill line and pump the oil into the tranny. Cheap, simple and clean.
 
Wow guys! Great tips. I might have one of those squirt type containers from my carpentry day's. Used a light weight oil for my nail guns. It came in one of those squirt bottles. I also will order that Coleman for sure. Thanks, Bob.
 
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