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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Crankcase plug is seized (flathead)
Post Info TOPIC: Crankcase plug is seized (flathead)
Lurkville


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Crankcase plug is seized (flathead)
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Hey crew, new to the forum. I own a 2001 TTR for my girlfriend to kick around. Just starting to tear down the motor, and found that the smaller plug (flathead) on the crankcase cover is completely seized. Tried a flathead amongst other things and can’t get it to budge. i can’t belive they used a flathead design for these.. oh well. I tried the search option but didn’t find any info.

 

what do you guys use to unscrew these? Is there a better tool? What are aome options?

 

thanks



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Moo


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Find a nice big flat penny washer that fits snuggly, think Wilkos sell some. Grip the washer with pliers/mole grips and use it to turn the plug. This gives you the biggest contact area and reduces the chances of the plastic gouging.

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TTRfan


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Exactly as Moo suggests biggrin

Just dived in to welcome you to the forum Dan wink

Brian



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Lurkville


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Thanks for the prompt response fellas, I have some lying around. Ill give it a shot in a few hours. I was wondering what it was that was gouging at the edges..... Is it a plastic coating?

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Moo


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The whole plug is plastic no



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TTRfan


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Interestingly Steve has a large plug in his second-hand parts bin that is made of aluminium - see here

Shame he hasn't got the small one in ali as well.



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Cubber


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Welcome to the forum, Dan.

Good job it's here for you, isn't it? wink

Hope you don't gouge the cover any.

Martyn



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tom13


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Google translator
In Aliexpres I bought aluminum plugs for an Allen key.

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Grandpa Tom

 
Lurkville


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Hey guys,

So here’s an update: I tiied a penny washer. Tried hammering it in til it was as snug as possible. Still didn’t budge and just stripped the plastic.

What’s my next best option? Should I drill it out?

Thanks

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mossproof


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I think that's the only option left. Sounds like it's damaged beyond redemption anyway.

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ttboof


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Maybe try a bit of heat if does come  out you have something until a new one arrives 



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Lurkville


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What’s the best way to drill this thing out considering it’s plastic? Should I try left hand bit?

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petenz


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hot air gun...sofen it might unscrew


.

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TTRfan


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Or try tapping it around using a chisel or screwdriver on its top edge where it is away from the generator cover! Being careful not to slip of course......



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