screwplug on left crankcase cover is over torqued :(

Hello everyone ,
Does anyone have a trick to get a screw plug on the crankcase off that doesn't want to budge? the aluminum is just slowly chipping away..booo
My next step is to put a grinder wheel to it for a second to square off the slot < then attack it with an air ratchet. My objective is to change the leaky gasket on the bottom end.

 

I've had some luck with a handheld impact wrench, like you can get at Princess Auto for 10 bucks. it's loosened many bolts that i figured would never come out. You have to give it a good shock, otherwise like you mentioned you'll just ream that aluminum right out. Good luck with it, I have the exact same bike so it seems

 

Exactly which plug are you talking about? You may be trying to remove something that shouldn't be...

 

Well i tried the ratchet , so I guess the impact is next. if that doesn't work I'm going to put an extractor bit on it and order a new plug.

I own the mechanics manual for this bike and it says , "remove crankcase screw plug on the left side" . In order align the "t" with the notched mark before I proceed with removing the cam chain,cam shaft and cylinderheads to get at the bottom end gasket.The gasket which is leaking more oil than anyone would want. I should note that this operation is on a '82 XS400 maxim .

Its clear to me now the clown that neglected this bike did not own a manual

 

solution! I removed the side crankcase cover..hahaha. to hell with that bolt cover.