Oil Change Gone Wrong

[Fin]

So it all went wrong on the 22nd of October when I thought I'd change the oil filter and oil on my XJ600. You may have seen my thread about what happened, the sump bolt threaded.

https://i.imgur.com/V5GVtVy.png

Devastated I came here for advice and it was a fairly simple process to buy a new sump and gasket for about £20.

A week or so later I put the gasket and new sump on, when doing this the gasket must have torn as it didn't seal properly and leaked properly.

Not needing to use the bike and needing to spend some time on the exhaust I left it, the gasket being more than a new sump I thought I'd try some gasket sealant from a tube.

If you've ever take off the sump of an xj600 you'll know there is an awkward bolt by the side stand which you can access with a ball joint hex key. Not being able to find mine I used my dads... Big mistake.
https://i.imgur.com/eV8IReF.png 07.01.17

Okay my fault for doing it up so tight but I used the same key to tighten it with and put in anti-seize (copper grease).

I had a quick tinker to try and get the end out the bolt but couldn't so left it a while.

On the 21st Jan I had a better go at getting the head out but was pretty stuck for ideas as access is so hard.

https://i.imgur.com/NRzcdDB.png

I tried to use a tiny cobalt drill bit on the end of an air rotary tool but the hex key was too hard. I then consulted facebook which were pretty clueless.

Skip to the 2nd of March, (day before my big bike test) I wanted to get it sorted so I had another crack. Hitting it lots with a centre punch trying to to make a dent I could drill into or tap it loose and use a magnet.
https://i.imgur.com/1LDF2gl.png
I then removed the side stand switch and used an angle grinder to cut a bit out the way, the switch doesn't need that much steel and It'll give me better access.

I didn't get it out and ended up enjoying my day off and doing stuff to my car.

Skip to last night where I managed to drill into it a bit with a bigger drill bit and a proper drill however the head seemed to have become one with the bolt.
Before I drilled any further and removed the softer bolt steel I thought I'd see if I can stick a bolt in and weld it or get someone else too if I cant.
https://i.imgur.com/QdlOSKW.jpg

'tack' welded in place I was ready to give welding the bolt in a go, would be difficult for me with my arc welder and 0 skill but I don't have much choice.

I have a look around for the best access and this is where I notice the big shit.
https://i.imgur.com/ht2aZXl.png

Only gone and cracked my engine hammering the shit out of it...

https://i.imgur.com/pALdylg.png

Anyone else managed to fuck up an oil change more than me?

Also what shall I do about the crack and bolt, I haven't tried welding the bolt yet. Expect I'll try and weld the engine back together although I imagine I'd have to get a different welder or at least rod.

[Bozzy]

Oh dear, sorry to hear that fella.

Didn't bodyguard cock his bike up trying to do something simple? I'll try to find the thread if it makes you feel any better.
____________________
2004 SV650S >>> 2009 Street Triple R

[Pete.]

I have to admit I've never seen anyone go from stripped sump plug to cracked engine cases in so few steps.

And you managed to break one of the only two tools you'd need!
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[RhynoCZ]

[Commuter_Tim]

Curious how it's always the magnetic sump bolts in these threads.
Commiserations.
____________________
The above post is most likely nonsensical.

I ride a Bandit 600... badly.

[P.addy]

Arcane is that you.

[Tbag]

What the hell is that Allen key made of?? chocolate

[Baggyman]

Ball head allens are not designed for final tightening or initial untightening, just for rapid "no load" screwing - the narrow bit is an obvious weak point. May just about be Ok with a snap-on but never with cheaper stuff

A bit late now but if you have limited clearance, you are much better cutting down a standard allen so it is short enough to gain access.


Looking forwards, you are going to have to remove and strip the engine. Worry about the problem allen when it is on the bench.

Options:
1. May be able to get a specialist to weld it
2. new cases
3. another engine from the breakers

Also, get the plug thread in the sump helicoiled

Also, is that welder current flowing through the ally engine? Lucky you did not get a silver puddle on your garage floor
____________________
Old fart
Baghira, modded GS1000 and the T150 I bought in 1978 when I was 21

[DRZ4Hunned]

This forum never ceases to amaze me
____________________
DRZ400-SM
FZS600

[Pete.]

[Pete.]

There's a big lesson here for people doing their home maintenance:

First and foremost - don't over-tighten stuff. People seem to think a sump plug will fall out because it's under the engine and holding all that oil in so they give it a couple of extra shoves to be sure. IT WON'T - it's no different to any other bolt in the engine, once tightened it stays tightened.

M6 sump bolts - 7 foot pounds same as any other. Even the weakest person can achieve that with a normal spanner and 2 fingers.

Sump plugs - fit a new damn crush washer. Every time. You can't flatten a sealing washer that's already flat.

Stripped sump plugs - get a sump plug repair kit off eBay for £20 and fit an over-sized plug. Contrary to what people think you won't fill your engine with swarf, it's perfectly safe to do it in the bike, it takes just minutes and you'll be on your way with a brand new plug and washer fitted in literally minutes.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[BTTD]

[Baggyman]

[P.addy]

[Rogerborg]

I'd definitely take the bike straight to Pete after you've bought it.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Pete.]

[dydey90]

[Baggyman]

[BTTD]

[Pete.]

[Baggyman]

[skatefreak]

I am suitably impressed
Don't suppose you could change some bulbs on my bike?

[nowhere.elysium]

[P.addy]

[Baggyman]