Help! Oil Filter Cover

[swid]

I started the bike after just finishing changing the oil + oil filter.  Then oil started gushing out of the filter cover.  Huge mess.  I stoped the bike, and thought I just didn't tighten those three screws tight enough...  So, I tightend them some more, and then I snapped off part of one of the bolts!  Now part of the bolt is stuck in the screw nut, and the other half isn't long enough to tighten another screw nut on to it.

I think the O ring was just bad, because when I got the filter cover off, it was ripped in two.

What do I do now?  How do I replace that bolt?

[Danny500]

There are many ways to remove a busted stud. If it's protruding out of the block more than a 1/4 inch, you could try heating the block with a torch at the threads (around them.. don't heat the stud itself) and then put some vice grips on it and back it out... then go to the hardware store and pick up a new one and loc-tight it back in the stock position.

If it's really, really bad... you may need to drill and tap the stud. Meaning, drill out the stud and re-tap (thread) the hole for a new (probably larger) bolt/stud.

If you get the stud out, you could use a new stud, or simply use a bolt.. makes it a tad easier to change things.

For future reference.

DO NOT OVER-TIGHTEN THE NUTS! They only need about 10lbs of torque.. not even on them. Check the wiki for proper specs... Basically hand-tightened is fine.

DO NOT EVER RE-USE THE OLD GASKET! Fram oil filters for our bikes come with a new rubber o-ring. Make sure the mating surface for the cover is free of dirt/debris before re-installing and use a light coat of oil on the gasket when re-installing so that as you tighten the cover down the gasket won't bind up or pinch anywhere.

Sucky situation, but if you do a search there may be other fix-it methods to the stud thing.

Good luck... 

[GeeP]

Remove the filter cover.

Carefully turn out the stud using a pair of Vise Grips or similar.

Buy a new stud from your dealer.

Replace stud.

Re-install oil filter cover.

Don't over-tighten the nuts this time.

(As you tighten the nuts, a little at a time, you'll notice that their resistance to turning gradually increases as the O-ring compresses.  Then, as the cover bottoms, resistance will increase very quickly.  Stop as soon as you feel the resistance increasing quickly.)



If this is your only transportation, you can temporarily replace the stud with a metric bolt of the correct length and thread.

[VSG]

I highly recommend that you replace the studs with bolts.  I knew enough not to over-tighten the oil filter cover and I still snapped off one of the studs!

There were enough threads left that I could get 2 nuts on it and back out the broken stud.  I went to the hardware store, found some bolts that were the same size and replaced them all.

Always use a new gasket!  I even used some RTV sealant to avoid any leaks.

[sledge]

Stick with studs. Strip the thread on one and you can remove and replace it. Strip the thread in the case.......... and the fun really starts 

[GeeP]

Stick with studs. Strip the thread on one and you can remove and replace it. Strip the thread in the case.......... and the fun really starts 

Precisely! 

In addition, the aluminum threads gall every time you remove and replace the bolts, regardless of lubrication.  Studs (obviously) prevent this problem.

[harryg]

Hi folks

I have been a lurker for more than a year and never posted any thing as i was learning things from previous posts.Though I dont have any experiece working on bikes,I have leared a lot by reading the posts from this forum and saved dollars on basic repairs and maintainance.

During my first oil change I also stripped a stud and was pissed at myself.After trying all possible things from my side,I couldnt get the other half out of the case .Before going to the last resort of drilling the broken half,I have used a a saw blade to cut a 'minus' on the protruding end and used a power tool with a flat head bit and simply removed.From my experience that would be the best solution.
(This techinque was suggested by someone in my websearch)

I have recently sold my 2004 GS500F and upgraded to a 08 Ninja650R.

I would like to thank every one in this forum for sharing their knowledge and experiences.

-Hareesh

[Danny500]

Hi folks

I have been a lurker for more than a year and never posted any thing as i was learning things from previous posts.Though I dont have any experiece working on bikes,I have leared a lot by reading the posts from this forum and saved dollars on basic repairs and maintainance.

During my first oil change I also stripped a stud and was pissed at myself.After trying all possible things from my side,I couldnt get the other half out of the case .Before going to the last resort of drilling the broken half,I have used a a saw blade to cut a 'minus' on the protruding end and used a power tool with a flat head bit and simply removed.From my experience that would be the best solution.
(This techinque was suggested by someone in my websearch)

I have recently sold my 2004 GS500F and upgraded to a 08 Ninja650R.

I would like to thank every one in this forum for sharing their knowledge and experiences.

-Hareesh

Good luck dude!!! Glad you fixed it. You're actually riding my next bike!!!! Hope it feels good.

[harryg]

It is indeed a nice and fast bike Danny500.I am enjoying every moment on this bike.

[swid]

Still don't have the bolt out...

I doubt I have enough room to use a saw blade to cut a minus in it.  I broke the top right one off -  there's not a whole lot of room to work with.  Is it safe to use a dremmel tool to cut the slit?  I'm afraid I'll send hot sparks into the oil filter holder and catch it on fire.  This is so frustrating.

[fred]

Still don't have the bolt out...

I doubt I have enough room to use a saw blade to cut a minus in it.  I broke the top right one off -  there's not a whole lot of room to work with.  Is it safe to use a dremmel tool to cut the slit?  I'm afraid I'll send hot sparks into the oil filter holder and catch it on fire.  This is so frustrating.

A dremmel would work. If you're worried about anything catching on fire, just cover it with some canvas or whatever other heavy fabric you've got laying around. Also, if you haven't done so already, go spray the heck out of it with PB Blaster. Then do it again. Then wait a few hours and do it again. The more penetrating oil you get on that stud, the more likely it is to come out... If I were you, I'd spray it with penetrating oil whenever you think of it between now and when you actually try to go extract it...

[GeeP]

Remove the oil filter cover and grab onto the remains with a pair of heavy Vise Grips.