[Suzukirider1]

Fill plug for final drive is completed stripped out someone must have torqued it on there with a damn impact. The other hole to the left, not the axel screw, where does that hole lead to? Can I fill hub that way?

 

[M109Dreamer]

Is the plug stripped or the casing? I think the plug is aluminum and would think that would strip before the case would.

 

[thevili]

Fill plug for final drive is completed stripped out someone must have torqued it on there with a damn impact. The other hole to the left, not the axel screw, where does that hole lead to? Can I fill hub that way?

Welcome to the forum, Cheers.. 🍻
The other hole is blind hole for use when that part is used on other Suzuki bikes,
so no go that way. IMHO the best way is use Helicoil or similar thread inserts system,..

 

[Suzukirider1]

Is the plug stripped or the casing? I think the plug is aluminum and would think that would strip before the case would.

Ok thanks it's just the bolt part to take it off. I just tried heating it up. That didn't even work.

 

[HyperPete]

Welcome to the forum, Cheers.. 🍻
The other hole is blind hole for use when that part is used on other Suzuki bikes,
so no go that way. IMHO the best way is use Helicoil or similar thread inserts system,..

I would drill oversize, tap, and use an oversize plug for the rear. There is not a lot of material for a Helicoil, maybe 8 - 10 MM thick?
Just my 2 cents & my personal opinion.

Ok thanks it's just the bolt part to take it off. I just tried heating it up. That didn't even work.

Welcome to the forum!

Try heating it, and then hitting it with something COLD, like carb cleaner (Not brake cleaner, that would produce toxic fumes)
The fast cool should break it free if it's stuck.
If it STILL won't budge, apply a mix of ATF & acetone and let it sit an hour (or longer) to penetrate, then try again.

 

[Suzukirider1]

Ok thanks everyone for the advice.

 

[Hogan109r]

It sounds like it is just stuck tight “breaker bar “
Acetone will take the gray paint off .

 

[Slave #1966]

If they are NPT. then the standard practice is to drill and tap the next size over then use a bushing that has the original thread size for the internal. I would cut it a hair deeper so as to bottom out on the hex for a cleaner look and use a brass bushing so it will not stick so bad. Aluminum is very sticky and Galles so easily.

 

[Zoom]

Did you strip the threads or just round the head off the bolt? If the threads in the cover are stripped it might be easier to buy a used one. If the bolt threads are stripped you can replace the bolt. But I think you're saying the bolt was so tight you rounded the head off, in which case I would just grab it with a pipe wrench or vice grips and get it out, then either replace it or file it down so another size wrench fits it.

 

[Joe RC51]

Don't use a Crescent wrench next time , use a box wrench.

 

[cbxer55]

Don't use a Crescent wrench next time , use a box wrench.

Same can be said for channel locks.