hi all sump plug rounded off so cannot undo any ideas how to get off the drain off one underneath

Edited January 28, 201511 yr by littlegadgi

You could try a slightly oversized star drive (torx drive) the plug is only aluminium so just tap the drive into the rounded socket and it will undo if your carefull.

Edited January 30, 201511 yr by jfc

i have ground a larger allen key down but just slips think previous owner over tightened may have to drill and left hand tap out last resort have done oil change via sight glass not ideal then blew out with airline

Try the above with a little heat, its aluminium so a hair dryer will work ! Doesnt take much as its aluminium.

Try hammering the head of the sump plug first, that usually crushes the washer slightly and so reduces the load on the threads. A few sharp blows are usually enough.

I have found the best solution to get an allen bolt with the internal hex has been wrecked is as follows.Take a short length of stranded copper wire AWG 16 or so strip back 3 cm, spread the strands of wire across the internal hex then take your allen wrench and hammer gently into the hex this will tighten things up so you should be able to undo the fastener.

The Torx bit works a treat, especially with alloy, Just be sure to order up a new sump plug to put back in

Take off the skid plate. Use a small chisel and knock it loose. From now on use the right size torx as it grabs better. I have seen quite a few minders carrying torx instead of allen. The torx gets a better bite the first try.

PS the oil filler plug can be used until you get the proper parts.

Edited January 28, 201511 yr by lineaway

Sounds like they should make them Torx to begin with.

Actually Dan, I think torx works better in an allen than in a torx. Try it if you have not.

Leave it in place.

The glass window in the left hand engine case will unscrew, so you can tip up the bike and drain the gear box oil.

What Lineaway said

Cold chisel always works