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Magnetic plug stripped.

in 912 / 914 Technical Questions 13 years ago
Anyone have suggestions as to how to get the old style, now stripped, plug out. Very tight space to get a drill into.

  • Re: Magnetic plug stripped.

    by » 13 years ago

    Hi Paul,

    There are two ways. One is to use a small set of vise grips (about 4" long) and grab around the edge of the mag plug. It will loosen right up.
    The second way is to take a Dremel tool with a cut-off wheel and cut a slot in the head. Then take a slotted screwdriver or a slotted tip on a ratchet and just unscrew it. I have done it several times and it works great. I use this method for many stripped screws. People tend to strip this out by not tapping the #40 Torx head all the way into the base of the mag plug head. The new style is a hex head like a bolt.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

    Thank you said by: Paul Tipton
      
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  • Re: Magnetic plug stripped.

    by » 13 years ago

    If you go to the "information" menu along the top of the screen of the Rotax-Owner web site, select "all videos" and scroll down to the video on "Magnetic Plug Removal", this is a great video on how to remove a stripped or stubborn Mag Plug as you describe. It's a "must see" if you have this problem or better yet to prevent yourself from having this problem in the future. They offer some real good tips on how to avoid the stripped Mag Plug issue all togeather!:cheer:
    Thank you said by: Paul Tipton
      
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  • Re: Magnetic plug stripped.

    by » 13 years ago

    FWIW,

    Getting a jammed in plug out was a real pain. Many owners cheat and never remove it, because it's tightness has scared them & they just hope there's no metal circulating.

    I couldn't accept taking that risk & Conrad Beale (UK Rotax guru) told me how to get it out.

    A long steel rod to tap the head very smartly indeed maybe several times is another dodge to loosen the threads, then (horrible, but practical) use a small chisel to make a handy cut/groove in the head edge. Then a suitable rod or solid screwdriver is used with light hammer to engage the groove and unscrew 'normally'. For access, best done with oil filter off.

    Now what next ? Well when replaced and trying it 'not so tight' it was weeping, but really tight as per book and it was a pig to remove.

    ANSWER & successful every year for the last three is to use a (fresh) Copper/asbestos washer same spec. as used under the Rotax oil tank drain plug. Re-torque to the same figure as drain plug, plus the usual wire locking. It NEVER leaks and comes out nicely for inspection at the 50 hour checks.

    mike hallam.
      
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  • Re: Magnetic plug stripped.

    by » 13 years ago

    Just as a side note, Most motorcycle and auto supply stores have metric copper washers in stock.

    Bill.
      
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  • Re: Magnetic plug stripped.

    by » 13 years ago

    I have used the 4" vise grip method with success. I first "tapped" the old stripped torx magnetic plug with a torx socket+extension and mallet . It helps to do this all at an oil change when the filter is off to get the most working area . Installed a new hex head magnetic plug so future magnetic plug inspections should be a breeze.
      
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