Oil Filter bolt stuck!! Need Help!

I own a 1981 Yamaha Maxim XJ650. It's been running great and i've slowly been fixing it up. A short while ago i decided to change the oil, when i got to the oil filter however, i couldn't remove the bolt holding the oil filter cover on. I've tried everything i can think of to turn that bolt, and i've only succeeded in prying metal off of the bolt head. I started off with the right size socket, but it was on so tight that i rounded off the ends of the bolt. Next i tried clamping pliers, i tightened them as far as i could and twisted. This only took off more metal. The previous owner obviously over tightened this bolt when he last changed the oil. Any ideas on how to get this off??

 

Not so much 'overtightened' as did not maintain.
When you do eventually get it off, use anti-seize or get a spin on adapter kit from chacal.

You need to be careful from this point forward.
You have two options really.
Bolt extractor set, that will dig into the existing metal you have, or
A stud extractor set, that you need to DRILL into the existing bolt, install an extractor and remove the bolt.
I would recommend trying the bolt extractor that will fit right on there nice and tight, and use an impact driver to crack it off.

 

What looks like a washer under the nut, is actually part of the nut, you might try using a small cold chissel & hammer & knocking it round, as it will have to replaced anyway.

 

I'll guess that you used a 12 point socket to try to remove it . Most people have these in their tool boxes, they are the most common. They don't offer much gripping power on nuts and bolts. If you have a difficult to remove bolt , always use a 6 point socket. They have more area to grip bolts without rounding the heads. Since the dammage has already been done the cold chisel and hammer would be my next option. Another method that has worked for me is to weld a new nut on the end of the bolt. Use a nut that will fit over the dammaged section and weld in the center of the new nut.

 

I had the same problem,I used a small "Pipe Wrench"once you get it to bite, it should loosen up for you

 

I had an extreme case of this. The nut ended up as a perfectly rounded circle. What finally worked for me was removing the header (for more angles of attack), cutting a fairly wide slot into the head of the bolt with a dremel tool, then using that slot with either a fat flat head screwdriver or something more aggressive if really stuck. Mine was terrible, and I ended up having to put a screw driver into the "top" of the slot coming in from the side as much as possible and then hitting the end of the screwdriver with a hammer (while a friend supported the bike!) until it finally turned. I have to admit though - after struggling with that cursed bolt for months, the moment it turned might've actually brought a tear to my eye.

 

My PO welded a socket, now the bolt is 3/8 drive, the only problem is the heat could change the "value" of the pressure relief spring inside the bolt, if this were used as a permanent fix.
(new ones are about $10)

 

Thanks Everybody, I'm heading back home this weekend and i'll be able to try some of these options. Thanks for all of the help. I'll let you know how it goes.

 

When i got my bike i had the same issue. With no success trying everything, i simply used my sawz all to cut a slit across the oil housing and then put a chisel in the slit and pryed apart till it broke off. went on ebay got a new used housing for cheap and bought the bolt thru parts unlimited for way less than yamaha. My bolt end was rounded too.

 

This is exactly my situation and your comment is reassuring and helpful! Here we go!

 

Another method is to use an angle grinder to remove the bolt head. There is a thin flnage on the bolt that you can use as an indicator of when you are nearly done grinding, so you don't cut into the filter housing. Bolt removal then becomes much easier.

 

another method mentioned in a recent thread is the bolt extractor socket.
I have good luck with them on rounded bolt heads

 

Thanks! Might see if our tool library has a set!

 

I think I got lucky. Impact driver with a six point socket turned the entire housing (spilling quite a bit of oil). Apparently the stainless bolt head galvanically welded itself the the aluminum. Putting it back with anti-seize between dissimilar metals . . .

 

Hi y'all! I've been having the same issue, that bolt hasn't been touched in 7 years and the housing is lined up in a way that tells me the bolt was EXTREMELY over-tightened. If the mangled bolt head wasn't enough indicator lol. I dont have access to a grinder or welder, nor do I have friends that can help me (I'm the only mechanically inclined friend that has their own tools.) I also definitely can NOT afford to buy those kinds of tools right now. I was going to try the chisel method someone mentioned. Any tips on doing so successfully?

 

I do have a socket Extractor set and it did nothing but tear the bolt up even more

 

I encountered more or less the same problem, but let it go for now and just changed the oil.
I plan to warm up the bike thoroughly and then try to loosen the bolt with an extension bar and maybe a few hammer blows.
When working on cars, I've always had good success with a 12-grip ring spanner when I felt like I was in danger of rounding off a bolt head.

So I was a bit surprised to read that the risk of rounding the bolt head is actually higher. I mean, the force is only transferred at specific points and not across the entire surface, but I always had the feeling that I was simply building up more grip using them.

 

You tried the blue crayon trick yet? That and force a nasty old socket on there with a impact removal tool.
https://www.harborfreight.com/6-bit...MI14rJtOyTjQMVFUP_AR1nwjGgEAQYASABEgLuW_D_BwE
It took two days of soaking my last 1983 project Yam, but it finally came lose.

 

https://www.abbuildingproducts.co.uk/bolt-extractor-set-11pc-3-8-sq-drive-or-spanner

These work if nothing else does.

 

The plan worked for me so far. I warmed up the engine thoroughly and then started working. I had previously obtained a suitable deep socket with a 1/2 drive. This, along with the larger ratchet and a hammer, gave the whole thing the right "oomph," and the bolt came loose after a few hits.

 

You can get a spin on oil filter kit for your machine. @chacal sells them but l don't know what the cost would be from the United States.

 

Like this should be available in Germany if you want to change to the spin on filter.

 

Thanks! I'll look into it.

 

You can use the 900 Diversion one too but the threads on the bolt need extended and the length of the bolt reduced where it secures to the crankcase.

 

Does this work for the XJ900? It says in the title it's for XJ bikes too, but the actual bike is missing in the compatibility list. I'm confused.
Couldn't find one in Germany but I'm fine with getting it delivered from the UK.
I wonder if this is road legal. You know, german TUV always has a say..

 

I don't see why it shouldn't be road legal. Contact eBay seller if you want to double check it fits your machine.

 

I am using the Diversion one.

 

Ok I sent a message. Can you elaborate further what you mean when you've adapted the diversion kit to the XJ 900F? Can you do this with ordinary tools, or do you need machinery? I mean you basically have to cut new threads on the bolt, right?

 

The bold from the Diversion pictured is too long I believe and needs to be shortened so the plate the oil filter rests on and the oil cooler distributor is tight to the crankcase and compresses the o ring. I need to check this but I think it will work.

 

I found an off-the-shelf part, but gubbered if I recall exactly what one.
I started by getting an XJ400 * filter plate and the bolt wasn't quite right so I used one off another model, obviously not a Diversion though.
They are out there...
<edit>
Or perhaps I shortened a Diversion one, I'm not sure now.
I put a thread up about it, if it can be found, the details are on it.
The spin-on filter I'm using is a Mann W67/1

*perhaps it was an FZR400

 

I was looking at other bolt's too but I have not found one yet, hopefully you will remember, be interested to know which one you used.

 

Found this I need to read it all.

https://www.xs400.com/threads/spin-on-oil-filter-oil-cooler-sohc.15184/

 

I think this is the answer looks like it will work.

https://www.ebay.co.uk/itm/19369851...vah_6wkpN86vXDEbutrpvjWsfqIqTgTRoCtBMQAvD_BwE

Mocal. Mocal is too short. The 900 Diversion bolt should fit but might need shortened, need to check next time I am at bike.

https://www.ebay.co.uk/itm/122641114562?_skw=mocal+oil+cooler+bolt&epid=651488011&itmmeta=01JV2YB12TG94VYKV13MA0KED5&hash=item1c8dfae5c2:g:15kAAOSwJY5jh05N&itmprp=enc:AQAKAAAA0FkggFvd1GGDu0w3yXCmi1fI4PRmCkCpk8u4dZVpBqXKIkftD500FzP8IfCVqBb27r+E/sK3snc47zYSL6rgy6VeeZ+H+Abo1DvgnaCQ/sRNA2BmT/y+DZvljIMxfiEFlR3q50bJkCGLKTuVcXj0+3K79HyvhtPPP5dIbelu4ArXQJgvgJyIAtbDvU0fTaPgz8M14+HkdqC6/G66RiOuYAdJ0Dn2eY5y2ajJVzUer4w6MVaYZ+pSiRXoF0UunfWnTZuseZENemkUV1xsfvZU6cU=|tkp:Bk9SR-KRrN7YZQ

 

That short bolt will be for the non-oil-cooler one.

 

You are right I just noticed that.