Rounded Oil Filter Bolt Head

Hey Folks,

Proud new owner of a '82 XJ650J with 50K+ miles. Was going to change the oil and filter but the bolt was so tight it rounded off on me. UH OH! Was thinking of tack welding on a larger nut over the top of the existing bolt head. Any suggestions before I go that route. Thanks in advance.

Patrick

 

Try vice grips first. If you can weld, you prolly have them nearby.

What size wrench/socket were you using?

 

I started with a 12 mm 6pt and it was Ok. The head had a small amount of rounding already, but it was so stuck and solid, I only made it worse when I tried to free the bolt. Tried tapping directly inline with soft hammer strokes, and then tried with the vise grips. Still nothing budging. My worst fear is breaking the stud off in the block. Maybe I should run the motor to put some heat into it.

 

Before it gets too far out-of-control, ...

Remove the Header Pipes and use a Pipe Wrench on the Shoulder of the Bolt.

Muscle the Old Bolt out of there.
You need to apply just enough grunt without actually soiling your pants.
The Bolt will break free and you win.

When you install the NEW Bolt you need to order from Len, ... apply AntiSeize to the last 2.5 cm of Threads and the Back-side of the Shoulder where it contacts the front of the Dome.

 

I had a similar problem as well. Taking off the header pipes helped me get the angle I needed with vice grips. I also used a ballpean hammer to lightly tap on the head of the bolt before I tried to spin it out. Getting the bike up to temp may help, but you won't be able to remove the exhaust then casue it'll be pretty hot.

 

Heating it will probably counter productive. The filter housing is aluminum and will expand more than the steel bolt.

The reason you're having so much trouble is the PO grossly over torqued it. If I recall right the spec is 11 ft-lbs. Not much more than snug.

The replacement bolt you buy from Chacal will also have a larger head making it less likely to round. Still don't over torque it though.

 

Or just cut a slot in the head with a dremel and use a big screwdriver to back it out...

 

I had the same problem, I used a 6" pipe wrench, and didn't have to take off the headers which was a bonus.

 

If the bolt is still good when you get it out, and you have a welder, just weld another nut to the top of the bolt. I've done that before and it works very well. Infact you can go a size bigger if you'd like. Or just replace it, they're pretty cheap.

 

12 point fractional socket try different sizes until you get to the size that just barely wont go over the head then tap it on, or an bolt extractor: http://www.amazon.com/Irwin-Industrial- ... 31-2712005
Sears used to sell a set but I dont see it on their website.
If you do decide to weld on a nut put ground as close to bolt if not on the bolt itself welding could damage electronics, battery and bearings better safe than sorry

 

Thanks folks. Removed the header pipes as Rick and some others suggested and used the pipe wrench. What I found out that the bolt assembly itself is also aluminum! NO wonder it rounded so easily. Once out I dress the head back to hex and and now I am able to use that 11mm wrench in my box that NEVER got any use. I back in business and didn't cost me any $$! Many thanks for the suggestions!