TRX300FW 1995 – Busted Drain Bolt in Final Drive

Hey guys,

I just finished rebuilding the ass-end of my bike. I take a lot of pride in doing things right and I go overboard in doing so. I buffed the rust off of every nut/bolt, changed anything that needed to be changed and painted everything that needed to be painted. The swing arm, final drive, axle, axle housing and brake panel have been given a new life.

So here comes the time when everything is assembled and I decide to put my drain bolt into the case. I hand tightened it and then used a small hand ratchet to snug it up. I was on cloud nine and ready to test drive my bike when I heard a "stick" sound.

Busted the bolt inside the case. I’m gutted. Murphy’s f***ing law!!!

The perfectionist in me wants to drill a hole in the bolt and try to extract it but I’m afraid of busting the small bolt extractor inside the busted bolt…

Any tips or tricks?