went to change the oil in the chain case on the sons 95 XLT. and low and behold the drain plug striped. So I started to remove the cover and I noticed that one bolt has be broken. It is not leaking and my question is how to remove both the plug and bolt?

Thanks in advance

When you say the drain plug is stripped do you mean the head is stripped out or the threads. If the head is stripped it's an easy fix, an easy out should do the trick. If the threads are stripped you'll need to re-tap the case.

The broken bolt can be removed with an easy out also.

The allen head is the thing striped. Got it out last year with no problem.

Pick up an easy out, they work great. I have a set and have used it a few times now, it's a great investment. Good luck.

I have the same problem on my 95 500. the chain case bolt is broke. It didnt leak before so I just put everythng back together and I am going to check it often to see if it is going to leak. Of course its the bolt that is the hardest to get to. If it leaks then I am going to rip the whole assembly apart just to get to the sucker!

Hi,
Just remove the cover and bring to the bench and use an E-Z out. Works every time. Later Rick

Bolt is not stuck in cover in is stuck in chaincase housing.

when you use an easyout get a lighter for a smoking pipe an apply conentrated heat to the broken bolt, the pipe lighter is like a very small tourch, Sid

I cant remember just what the drain plug looks like on your sled. Is the plug in the cover or in the case that you get at from underneath? I think it’s in the cover so I’ll go with that. After you get the cover off and on the bench you should be able to get the drain plug out with a vise gripes. As for the broken bolt, they make an easy out kit with left handed drill bits. If the bolt doesn’t come out with the drill then you use the easy out. Can you fit a drill with a bit in there, or will you have to take the case out of the sled?

Hope this helps :div20:

im a welder, heres a little trick if you have a mig welder, place a nut over the broken bolt and put some weld into the inside of the nut, wait 10 seconds and unthread it, the heat makes it easy to remove plus now you can put a wrench on it

Might be easier to pull the chaincase and fix it on the bench.

If it's toast I have a couple kicking around.