Stripped oil cap

[LoneWolfRider]

Stripped oil plug - just bought a 91 KDX 250 - any ideas to ensure I don’t mess with the metal. Here’s a pic

[mxsteve1968]

pull the cover, drill the plastic, carefully melt it out with a propane torch.

[LoneWolfRider]

pull the cover, drill the plastic, carefully melt it out with a propane torch.

That’s what I thought- thanks.

[JoeRC51]

You should be able to spin that out of there with an awl without taking the clutch cover off.  No fire needed.   

[Confederate]

Heat up the end of a big blade screwdriver and push it in to make a slot in plug, remove, let cool. Then put back in and screw out. Easy.

[LoneWolfRider]

Heat up the end of a big blade screwdriver and push it in to make a slot in plug, remove, let cool. Then put back in and screw out. Easy.

I like your idea much better and will give it a whirl. The kid I bought the bike from definitely muscled everything on nice and tight - the one plastic I couldn’t believe how tight it was - but anyway - awesome bike and I didn’t pay for it to be perfect! Thanks

[slothspeed]

I like the screwdriver idea. You could also use the screwdriver(Not heated) and fill the rest with hot glue gun.

[hondaxr650rrrr]

If the screwdriver does not work you could try and drill a hole in the remains of the cap and use a four flute easy out.

[S.O.A.N.Z]

looks really well maintained

[JoeRC51]

12 hours ago, S.O.A.N.Z said:

looks really well maintained

That oil cap does make me wonder if the oil was ever changed again after the cap broke.  ?  I've been given a couple of bikes over the years , a several year old YZ125 and an even older YZ175 , both were nicer than this.    ?

[jumper12]

Try a left hand drill bit. Go slow, that may back it out. Drill through the center of the damaged plug. 

[LoneWolfRider]

Try a left hand drill bit. Go slow, that may back it out. Drill through the center of the damaged plug. 

We’re all good - the two screw with vise and screwdriver trick was the winner but all your ideas were great thanks. Oil didn’t look too bad - doesn’t look like he rode it much - def crashed it a bit. No surprise - these bikes aren’t for everyone. Buy the way this is my project bike I bought off some kid so dirty just means cheap and probably a bit of extra maintenance. But I agree with your comments. Thanks again all!