Stripped oil screen bolt

While doing an oil change today I had trouble removing the bottom oil screen bolt. I was using an 8mm hex socket and stripped the bolt out. Can anyone give me some ideas on how to remove the now striped bolt....Heat.... will this melt the screen? Maybe a torx socket driven in ...will this stretch the bolt head and jamb it in the case?

any other ideas....

I just finished this same repair. As Ret says try an impact wrench however if this fails (as mine did) use a very sharp punch and strike the screw at as perpendicular to the screw axis as you can. The sideways impact should be in the loosen direction, however remember that the impact of the screw in it’s thread and seat, will slightly “re- size it” That is a good thing with galling. I waited util the replacement screw was in hand before attempting this repair. You will find that this screw is really soft and buggered one has no place on your $8000 bike

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01 KTM 520

Originally posted by bramps:

While doing an oil change today I had trouble removing the bottom oil screen bolt. I was using an 8mm hex socket and stripped the bolt out. Can anyone give me some ideas on how to remove the now striped bolt....Heat.... will this melt the screen? Maybe a torx socket driven in ...will this stretch the bolt head and jamb it in the case?

any other ideas....

Tried to do the first oil change on my new 2001 520exc...was very careful to use a good fitting 8mm allen to remove the short screen drain plug. Yep, it now a round hole with no way but to use an easy-out or chisle it out. I went to the KTM dealer to get a replacement. They had one. THE REPLACEMENT DRAIN PLUGS ARE STEEL!!! not the soft aluminum stock plug.

Originally posted by bramps:

While doing an oil change today I had trouble removing the bottom oil screen bolt. I was using an 8mm hex socket and stripped the bolt out. Can anyone give me some ideas on how to remove the now striped bolt....Heat.... will this melt the screen? Maybe a torx socket driven in ...will this stretch the bolt head and jamb it in the case?

any other ideas....

2001 520exc short screen drain plug. I stripped the 8mm socket in my 520 also. I carefully used a small sharp chisl to break it loose. It was so soft I would have bet it was aluminum...I was wrong. It is steel, but very soft. I am going to look into having one machined from stainless steel.

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