Stripped Muffler Drain Plug

2684 Views 5 Replies 6 Participants Last post by Tozguy, Sep 7, 2021

wireman

Discussion Starter · Apr 18, 2015

Hi everybody , I used the wrong size Allan wrench , I usually remove it once in while just to oil it , keep it from ceasing , now the head is stripped any ideas how to remove it. There isn't enough sticking out to get a plier on it, I was thinking of welding a nut on it but kinda hesitant hooking a welder on the bike because of electronics . Thanks for replying :sad: want to be :yahoo:

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Factoryrat

· #2 · Apr 18, 2015

Ditch that stocker and install a shiny new slip on!

Sent from my Nokia 6110

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flashmann

· #3 · Apr 19, 2015

Several options...you can grind down an "easy out" to fit whats left, if its inch, find a metric that you can pound in, or vice versa. Or grind down a slightly larger Allen wrench on all six sides till it just barely fits, pound it in, and, prior to trying any of the mentioned ideas, heat with a torch. I have even beat in a torx in an Allen in times of desperation.

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challenger1

· #4 · Apr 19, 2015

should be able to weld on nut if you disconnect the battery
does anyone know where you can purchase a RJWC slip on exhaust

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northern pointer

· #5 · Sep 7, 2021

Drill a small hole at center, then use a screw extractor. It's like a drill bit, but the threads on the exctractor will bite into the hole and remove the plug.

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Tozguy

· #6 · Sep 7, 2021

Just drill a small (1/8'') hole in the plug and leave it like that. Any condensation will then sputter out the hole without accumulating in the muffler. The hole is not big enough to effect noise or performance. Just check the hole every once in a while to make sure it is clear.
Many motorcycle mufflers come with a small drain hole like that but no drain plug.

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