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  • 2 Post By ashwinprakas

Thread: Dealing with Deformed Oil Drain Bolts.

  1. #1
    Rusted ashwinprakas's Avatar
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    Lightbulb Dealing with Deformed Oil Drain Bolts.

    From my recent experience's I'd conclude that this is going to be the most wanted DIY of all times for beginner's, cause this is a common mishap and sometimes can be very frustrating to overcome, especially if you'r a newbie like me.

    Recently I decided to change the oil in my 5month old ZMA. And to my surprise the oil drain bolt was tightened shut with so much force by the inexperienced SVC guys that this is what the bolt looked like.

    (Pics taken after removal)







    It was over tightened so much that the O'ring was almost squeezed to non existence. And looked like a thin layer of paint.



    So coming back to topic, even thought tried to get it off with a box spanner.
    (Always use a box spanner when dealing with Aluminium bolts/nuts cause with any other form of spanner it can easily get deformed like seen in the above pic's)



    It was pointless cause when we reach a particular point of torque the spanner would start slipping. So in short it was pointless and hopeless and would only get me in a much more worser condition if I kept going at it.

    At this point it was of no use taking the bike to SVC cause they said that the cover bolt could be removed at a 50/50 chance by hammering in which the risk was cracking the engine cover. So normally at this point beginners like myself would start feeling all other sorts of negative emotions ranging from simple hopelessness to blaming ourself for choosing the particular model of bike etc.

    But no need to worry guys, cause there's a safe way out of this. As we all know the bolt is made of a weaker metal compare to the engine cover so with proper force we'd be able to break off the inside thread of the cover bolt and that too in a safe way rather than going by the SVC method by trying to break off the whole bolt by hammering.

    So here's what we should do.

    1. Place a bar of the below sort, on top of the tappet bolt, just like we do when we were trying to remove it before.



    2. Then using a hammer hit the other end of the rod facing us with minimal force, just tapping it a few times would do, since the material is not that hard.



    The point of the above is to equally distribute force on the cover bolt so that the inner threads break off and at the same time without causing any harm to the engine cover.

    3. After completing the above process, using the box spanner once again, try to remove the bolt, and to you'r surprise the bolt will start coming off with ease. And in some rare conditions the bolt will just keep on rotating and wont come off, then just pull it out using our fingers is enough.



    Now since you've gotten the bolt out, oil will start to gush out, which should be collected using a collecting pan, so keep it ready before starting out the whole procedure. And once all the oil along with the restrainer and everything else has fallen into the collecting pan, slowly using a bit of clean cloth run you'r finger around the oil drain window, and wipe off all the broken off thread from the cover bolt.

    Now I hope you guys know the rest, if not then refer to the video link given below.




    CREDITS

    Aneesh Bro (If it were'nt for his tool box I'd be literally screwed.)

    PS Raghavan Sir (Calling him is like dialing 911 for me, no matter what the problem at hand, he's always got a remedy.)

    BAJAJ (For making the above DIY video.).
    rreneav1987 and YashwanthBK like this.
    Motorcycling Experience:
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    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    The Ride was Good, but Life is short, spend it Wisely!
    Adios Comrades!
    A.P. 2018

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    DIY approved
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    good one bro.. I just take it to the mech pay 20 rs and he goes through all the pain stated by you .
    Cheetahs are faster but the lion is still the KING

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    You should've posted this 2 months ago when I was getting frustrated with my jammed & deformed drain-nut.. Helpful piece of info!!
    Its the fusion of a two wheeled machine & a human being which creates a true biker.

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    Quote Originally Posted by Vishakh View Post
    good one bro.. I just take it to the mech pay 20 rs and he goes through all the pain stated by you .
    Take caution bro, and make sure, the nut is not overtightened by the mech's. The reason for them doing so is cause they usually deal with drain bolts that are of harder material, but in some bikes, like ZMA and all, the nuts are made with cast aluminium and can get stuck due to deformation.

    Quote Originally Posted by Abhijeet Bhattacharjee View Post
    You should've posted this 2 months ago when I was getting frustrated with my jammed & deformed drain-nut.. Helpful piece of info!!
    Sorry bro, as you can see on the date's recorded on the above pics, the above incident happened just a few weeks ago. Anyways hope you've already sorted out you'r issue, if not then please post pic's and everyone here will be able to help you out.
    Motorcycling Experience:
    2000 ~ 2017 Y2K Kinetic Zoom (Disposed at 15k)
    2011 ~ 2015 Hero Honda Karizma R (Sold at 56.5k)
    2013 ~ 2014 Bajaj Discover 100 4G (Sold at 16.5k)
    2015 ~ 2017 TVS Wego (Totaled at 18k)
    2015 - Bajaj Pulsar 220F (Currently 31k) < Garage Queen!
    2017 - Bajaj CT100B (Currently 21k) < 'Golden Quadrilateral' Runner!

    The Ride was Good, but Life is short, spend it Wisely!
    Adios Comrades!
    A.P. 2018

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    Quote Originally Posted by ashwinprakas View Post
    Take caution bro, and make sure, the nut is not overtightened by the mech's. The reason for them doing so is cause they usually deal with drain bolts that are of harder material, but in some bikes, like ZMA and all, the nuts are made with cast aluminium and can get stuck due to deformation.



    Sorry bro, as you can see on the date's recorded on the above pics, the above incident happened just a few weeks ago. Anyways hope you've already sorted out you'r issue, if not then please post pic's and everyone here will be able to help you out.
    i got the drain-bolt changed from the SVC when I cudn't do it myself.
    Its the fusion of a two wheeled machine & a human being which creates a true biker.

    Fine me on facebook: https://www.facebook.com/krazzykid.abhijeet

    Pulsar spare parts price list (indicative only):
    http://www.scribd.com/doc/42303845/P...re-Parts-Price
    http://www.scribd.com/doc/99085008/Bajaj-180-Pulsar-UG3

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