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Stripped oil passage cap on bottom end. Solutions?

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ka-ja:
+ the above, I remove my 400/4 seized one using a die grinder cutter to remove the head and "groove" it internally, then collapsed it in and off the thread, luckily, I had a tap that cleared the threads afterwards

Trigger:
You should never try to remove these with a impact driver as, these are thin alloy and can crack. I must of removed thousands of these over the years. The early 750 had a 17mm head which was easy to remove then, Honda changed them to a 14mm head making, them more difficult to get a grip on.
Heat the around the cap to 250 degrees to soften the o'ring  and break the seal and use a metrinch socket which grips the flats ;) 

K2-K6:

--- Quote from: Trigger on February 14, 2022, 10:20:42 AM ---You should never try to remove these with a impact driver as, these are thin alloy and can crack. I must of removed thousands of these over the years. The early 750 had a 17mm head which was easy to remove then, Honda changed them to a 14mm head making, them more difficult to get a grip on.
Heat the around the cap to 250 degrees to soften the o'ring  and break the seal and use a metrinch socket which grips the flats ;)

--- End quote ---

Agree with this,  trying to conserve the original method of turning anything is primary in getting them undone for many design.

Going straight to cutting or damaging as a strategy is often limited in my view. From a engineering workshop perspective in trying to recover broken, damaged, or otherwise impaired fixings, it's often not without compromise. The right decision first will help keep you away from some limitations in practical engineering solutions and avoid needing replacement ultimately.

ka-ja:
Not forgetting that any form of turning a seized gallery cap will cause further damage if it is the threads that are seized and not the o-ring surfaces

K2-K6:

--- Quote from: ka-ja on February 14, 2022, 07:07:17 PM ---Not forgetting that any form of turning a seized gallery cap will cause further damage if it is the threads that are seized and not the o-ring surfaces

--- End quote ---

That's unusual as the design on most I can think of have the threads inside the oil gallery (the internal side of o-ring) with the ring sealing those from atmosphere and contamination. Clever those Japanese  :)

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