Oil Plug Nightmare - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 9 (permalink) Old 04-22-2019, 11:06 PM Thread Starter
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Oil Plug Nightmare

Dear VN750 Friends,

I’ve had just about the worst day in the world at this point. I was changing my oil in the Vulcan and went to put back on the oil plug and snug it and it snapped right in half. The inner bit that is broken is still in the motor and stuck and I have no idea on how to remove it. I attached pictures of the plug situation in the motor. Please any idea will help I’ve tried spinning it with a chisel and hammer and it didn't budge a bit.
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Sincerely,
Michael Ranalli
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post #2 of 9 (permalink) Old 04-22-2019, 11:31 PM
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Possibly a large 'easy out' bolt extractor:

Measure the diameter of the hollow part of the plug and the buy one that the small end will adequately snag and engage to twist out the plug.

https://drillsandcutters.com/8-carbo...b693ecd652915f

https://drillsandcutters.com/9-carbo...5c8eca40af96ba

https://drillsandcutters.com/10-carb...642b416a5416a1

Don't get one too small or it will go too deep and snag the internal threads of the case.
Too big and it won't snag enough of the plug to get a good grip.

"I need yo clothes, yo boots and yo motocycle."- Uncle Bob

Last edited by roadpouring; 04-22-2019 at 11:36 PM.
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post #3 of 9 (permalink) Old 04-22-2019, 11:51 PM Thread Starter
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Quote:
Originally Posted by roadpouring View Post
Possibly a large 'easy out' bolt extractor:

Measure the diameter of the hollow part of the plug and the buy one that the small end will adequately snag and engage to twist out the plug.

https://drillsandcutters.com/8-carbo...b693ecd652915f

https://drillsandcutters.com/9-carbo...5c8eca40af96ba

https://drillsandcutters.com/10-carb...642b416a5416a1

Don't get one too small or it will go too deep and snag the internal threads of the case.
Too big and it won't snag enough of the plug to get a good grip.
My neighbor suggested this exact thing. I questioned it they made the appropriate size. Thank you for the links I’m thinking am number 8 would be the appropriate size. Any suggestions on size. Measuring the inner diameter of this would be quite hard beings it’s recessed in the motor. Thank you again.


Sincerely,
Michael Ranalli
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post #4 of 9 (permalink) Old 04-23-2019, 12:24 AM
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Quote:
Originally Posted by Mikes Dji View Post
My neighbor suggested this exact thing. I questioned it they made the appropriate size. Thank you for the links Iím thinking am number 8 would be the appropriate size. Any suggestions on size. Measuring the inner diameter of this would be quite hard beings itís recessed in the motor. Thank you again.
I use bore gages to measure hole diameters, but to get a measurement that's close enough in your case, use a pair of needle-nose pliers, tweezers or hemostats to grip a strip of index card or similar material. Cut the ends off of the strip systematically until the strip can be inserted across the internal diameter. Pull it out and measure the length of the strip with a ruler.
Or you could use a piece of soft wire and bend it in the shape of an 'L' and likewise snip the short end until it fits the internal diameter of the plug, then measure.

"I need yo clothes, yo boots and yo motocycle."- Uncle Bob
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post #5 of 9 (permalink) Old 04-23-2019, 01:37 AM
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Depending on what tools you've got lying around, you could cut a slot up the side of an appropriate piece of pipe with an angle grinder/hacksaw, then slide the pipe into the hole so the last leg of the plug slides into the slot you cut. Add pipe wrench, and spin it out.
Good luck with whatever methods you employ.

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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post #6 of 9 (permalink) Old 04-23-2019, 02:39 AM
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Fortunately that plug is aluminum. I changed the oil in a Vulcan 750 every 3000 miles for 108,000 miles and never had a problem with that plug. But it is very soft. The main thing is to not damage the threads in the case. Then you will really be in trouble. I probably have some kind of tool laying around that would get it out. I'm thinking of a wood chisel or gasket scraper ground down to fit tight, and with sharpened edges. Something that will dig into the soft aluminum. If it won't turn by hand, put a crescent wrench or visegrips on the tool and gently tap it toward the left. Unless the threads are already damaged, it should come out.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
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post #7 of 9 (permalink) Old 04-26-2019, 11:27 PM Thread Starter
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Quote:
Originally Posted by roadpouring View Post
Possibly a large 'easy out' bolt extractor:

Measure the diameter of the hollow part of the plug and the buy one that the small end will adequately snag and engage to twist out the plug.

https://drillsandcutters.com/8-carbo...b693ecd652915f

https://drillsandcutters.com/9-carbo...5c8eca40af96ba

https://drillsandcutters.com/10-carb...642b416a5416a1

Don't get one too small or it will go too deep and snag the internal threads of the case.
Too big and it won't snag enough of the plug to get a good grip.

Thank you all so much for your opinions and help. Special thanks to roadpouring I ordered the NO. 8 easy out (Bolt Extractor) from the site suggested. Came In one day. I ordered the new plug (11012-1483 CAP,OIL FILTER (Kawasaki)) from Partzilla it came in 2 days and now the bike is back up and running. Pictures attached of the parts of the cap left. And once again thank you all.
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Sincerely,
Michael Ranalli
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post #8 of 9 (permalink) Old 04-27-2019, 12:08 AM
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Quote:
Originally Posted by Mikes Dji View Post
Thank you all so much for your opinions and help. Special thanks to roadpouring I ordered the NO. 8 easy out (Bolt Extractor) from the site suggested. Came In one day. I ordered the new plug (11012-1483 CAP,OIL FILTER (Kawasaki)) from Partzilla it came in 2 days and now the bike is back up and running. Pictures attached of the parts of the cap left. And once again thank you all.
I'm very happy to be of help.
So many others in this forum have helped me.

"I need yo clothes, yo boots and yo motocycle."- Uncle Bob
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post #9 of 9 (permalink) Old 04-27-2019, 12:16 AM
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From the photo and for those in the future who may have the same problem, it looks like a #9 easyout would have been more appropriate.

But the #8 did the job and for that we can be thankful!

"I need yo clothes, yo boots and yo motocycle."- Uncle Bob
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