Crankcase crack at drain plug. HELP!
So I have a crack in my crankcase right at the drain plug. Sounds pretty much exactly like Moriver's post from last year: can't post a URL linking it because I'm a new member, but search "oil leak at crack in drain plug"
like his, mine runs from the flat shiny surface where the washer seats, right up the front of the cylindrical housing that protrudes down. Overall its not a big crack, but its involvement with the threads has me worried. I'm opting towards JB weld just because that way I can do the work myself and take all the time and care that is needed. Ive heard several success stories with JB in the past.
My plan is this: drain the oil and let it drip for a few days. Lay the bike on its side, maybe at a slight decline, so all the remaining oil will not be at the drain plug leaking through. clean well, take out some material and score the surrounding area with a dremel, and then apply 2-3 coats of JB over a few days.
my question is whether i should focus on patching only the crack on the front of the housing (the part of the crack that is visible when the plug is in, and the part that leaks). Or should i focus on fixing the crack on the shiny washer seated area as well and up into the threads. Or I could also do the front housing crack first, then drill and tap a smaller hole in the original plug. then JB weld the original plug into the hole and just drain oil from the smaller hole from now on.
also what should I do before laying the bike on its side (90 degrees) or a little more like 100-110 degrees on a small decline. drain the carb? anything else?
ANy thoughts or insights are GREATLY appreciated. local shop estimated $1000 to fix it, but I'd rather not do that If i can get away with it. I do local rides mostly so I wont be stranded too far. Love this bike, it's got so much life left in it.
2003 KLR, 14,000 miles: