(I could have sworn I posted this a couple of days ago, but I can't find the original post.)

Although I've removed the chaincase drain plug on my Pro-X many times without trouble, I somehow managed to strip the head (where the allen wrench fits) this past weekend. What are my options? If I take off the chaincase cover, will I be able to grasp the other end of the plug with a set of vise-grips so that I can at least loosen it a bit?

clean out any dirt that my be in the hole and bang in a torques bit , if that doesnt work drill a 3/16 hole in where the allen goes and use a easy out. It will come out no problem, just dont use vicegrips from the inside. THis is exactly what I had to do on my first chain case oil change. flop the sled on its side and work on it , it makes life much easier.

Your original post was probably lost when the new server took a crap. I figure at least a few ours of posts if not all day are gone. XC-Mark is right on. I had to do this on mine as well. I took mine off though as I needed to see what gears I was running anyway(bought used). Good luck.

XC Mark has your answer.

I would suggest you take the cover off and thoroughly clean all the grime and metal out of your chaincase. Inspect tha chain and gears closely.

While the cover is off, drill the hole and use an easy out like described above. Install a new plug with o-ring. Clean everything and reinstall the cover. Add synthetic gear lube and you are on your way.

Next time you decide to change the chain lube don't remove the drain plug. Just remove the cover, clean and inspect everything, bolt the cover back on and add new gear lube and you are on your way. When you remove the cover and see all the metal in the chaincase you will realize that just draining he oil doesn't get much of the metal out of the case. This method takes 15 minutes longer but your chain and gears will last twice the miles.

PS. You cant get ahold of the plug from inside the chaincase. And if you could it would likely destroy the threads in the case and cause you more grief.

You could try to find just the right flathead and hammer it into the plug then turn.

Thanks for the useful advice. My weekend project is all set: I'll take the pipe off, I'll flip the machine on its side, I'll remove the chaincase cover, and then I'll try the torx bit and/or the easy out method and/or the flathead with a hammer method. One of those should work, and they all sound a lot better than the vise-grips procedure.

Cadd

Take the cover off with the sled on it's skis. The oil will drain out the hole in the tub into your drip pan. Clean the muck out of the chaincase then flip the sled up on its side. Use a little Break Clean or Carb cleaner to dislodge the solids. It will only take a couple of paper towels to wipe the inside of the tub and all will be good.

you could also try a left hand drill bit, depending on how tight you put the plug in last... i would be a little leary of "pounding" a torx bit into the the chaincase plug, that is alot of hammering on your driveline, not to mention ruining the wrong tool for the job. just my .02...

Something that helped me when I was in this spot, was to take a cold chisel (sharp) and smack it with a hammer (CCW direction). The sharp blow will usually get it started and from there it should nearly be able to be removed by hand. Of coarse I replaced the plug with a new one.

Yes I know that you should take the chaincase cover off to inspect and I do. I just like to be able to drain the bulk of the fluid first to minimize the mess.

Same thing happen to me and I just drilled it out and used the easy out. Worked just fine.

That happened to me on my old 97 XCR 600. A bud asked me why I tried in the first place, I said so I didn't have to take the time to clean up the mess..... Since then I just take to cover off. As the others have said you should anyway and the mess isn't that bad, most of it leaks out just as it would had you taken the plug out.

My rev doesn't even have a plug.

That happened to me on my old 97 XCR 600. A bud asked me why I tried in the first place, I said so I didn't have to take the time to clean up the mess..... Since then I just take to cover off. As the others have said you should anyway and the mess isn't that bad, most of it leaks out just as it would had you taken the plug out.

My rev doesn't even have a plug.


I'd just leave it there It dosen't leak right?