Drain plug went inside transmission

[kendunn]

The worst problem I have had with my 06 GG 300 has been the stupid drain plug. Well today went from bad to worse. When I tried to remove it it was very tight but instead of rounding out it broke off. I tried to drill it out and the stupid thing went up into the motor. Took the clutch out thinking I could get to it, but no. Does anyone have any ideas how to remove without splitting the cases? Thinking I may try to drill out the drain hole larger and see if I can flush it out. Of course when I tried to put the clutch back together I broke the basket. Bad day. Want to hear something else? Friday I was at a Harbor Freight trying to find a set of left handed drill bits that would have kept this from happening.

[PEB]

Split the cases, it is fun.

[gasgasman]

Bad day for sure.
Unfortunately, you will have to split the cases.
There are no openings in the case halves to fish the plug out.

The magnet on the plug is probably stuck to a gear.

[Zman]

It is a long shot, but see if the diameter of the shift shaft is larger than the O.D. of the threaded drain plug. If the plug is smaller you can pull out the shift shaft and try to fish the plug it out with a magnet. That is providing you were using the magnetic drain plug. If not you will have to split the cases.

[kendunn]

I'm pretty sure it wasn't using a magnetic tip, I had replaced it and couldn't find one with a magnet (I have 3 of these bikes so it could have been one of the others).

[jyellard]

I did the same thing on my bike with less than 20 hours on it. Never again will I drill out a plug with out left hand drill bits. You will have to split the cases. Mine was stuck to a gear due to the magnet.

ENJOY!