I just went through this with an 81 XJ550. To make matters worse, the 
engine was filled to the top with gasoline when I bought it, so heat was 
not an option.(I had drained the crankcase, but I knew the oil filter case 
was full of a gas-oil mixture.)

Sears sells these neat-o easy outs for bolts. They look like sockets that 
are reverse-threaded inside.  You tap one on the bolt and then put your 
socket wrench on it and it twists on tighter as you turn counter-clockwise. 
At least that's the idea. Mine just rounded off, but yours may give in and 
turn.

I ended up putting a notch on the left side of the bolt, you can use a 
dremel or even a drill, and then I put a chisel in the slot and tapped it 
until it slowly turned off.I bought a new oil filter bolt on-line that was 
supposed to fit my bike, it was an Emgo, I think, but it was too long and 
left a gap. I returned it and ended up buying an entire bolt and canister 
unit on Ebay from a guy parting out a bike.

I filled the crankcase will drain oil because of the gas in it, and when I 
got the bike running and it was time to fill it with fresh oil I couldn't 
get the bolt off again! And it was I, a non-gorilla, who had put it on! 
Luckily, my Sears easyout worked, but I strongly recommend taking some 
measure to make sure it doesn't freeze on again. Maybe someone can suggest 
a product or gasket. I sold the XJ; don't know how it's going to go for the 
current owner 3,000 miles from now, though.



On Friday, June 29, 2012 7:56:23 PM UTC-4, bikerman wrote:
>
> I am trying to remove the bolt in the oil filter canister but it will 
> not move. I am afraid of twisting it off. Anyone have any suggestions 
> on how to get this out without damage?

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