Dave wrote on 03/15/17 at 10:48:47:First......go get a new drain plug bolt.....you are going to need it.
You might try riding the bike so the engine is warm before you try to remove it....the aluminum expands more than the steel, and it mght be a bit looser.
If I was in that position and a "quality" set of vice grips didn't get the job done....I would weld a nut on the end of the bolt. Lay the bike on the side, and arc or mig weld on a large nut. Have a wrench handy and loosen up the drain bolt before it cools off. If you don't have a welder, take your new drain bolt, a large nut and matching wrench (best if the nut does not have shiny plating on it), to a local weld shop, or mechanic who has a welder, and get them to help you. No hacks or inexperienced guys......somebody who has been around a while.
OK - a couple comments. Regarding stewmills posts, I tried one and three already. I like the idea of what I see in his second picture - but I don't know what that is. I feel like I could make something like that work with enough leverage and tapping with a hammer. Maybe drilling into the bolt and using a set screw with whatever this tool is. Looks like a could maybe make something like this.
My neighbor is a welder (unsure of his experience as it is not his primary profession.) He is concerned about welding around the aluminum. This will be my last resort.
God this is a stupid thing to have to deal with.
What do you guys think about these:
http://www.sears.com/craftsman-10-pc-damaged-bolt-nut-remover-set-low/p-00952...All the auto parts stores have bolt removing sockets with teeth, but then it is a clearance issue. Anyone think these would work at an angle - with my 6" extension?
ugh...gonna explore something like that second photo that stewmills posted. Just gotta find out what the hell that is.
Yeah I'm a newb to the savage, but not a newb all together. And not cheap - just thrifty (and broke).