Drain Plug Casing, cracked. Piece fell off... KLR 650 2005 - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 32 Old 04-11-2014, 03:30 AM Thread Starter
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Drain Plug Casing, cracked. Piece fell off... KLR 650 2005

Before I begin I will say that I have already read both of these threads on this amazing forum:

this is kaseman's "case" from 2013

http://www.klrforum.com/showthread.php?t=19898

and

this is vinson1213 from 2011

http://www.klrforum.com/showthread.php?t=12019

And in advance i would like to apologize for my stupidity, this is my first motorcycle (bought it used) and I am absolutely clueless about many things.

I have found both of these forums very useful, however I decided to start my own thread, since I am not sure that I should follow Kaseman's approach (JB weld the whole thing and use piggy back plug.) and I feel that my problem is "in between" the two.

So here's what happened. I was changing the oil and when I was using the ratcheting tool to secure the sump plug, I heard something crack. Weirdly enough I couldn't finish securing the plug - no matter how much I turned it wouldn't fasten. So I thought it was just the ratcheting tool. So i filled the bike with two liters of oil, ran the engine, then decided to take a look at the sump plug again and it was leaking. At this point I stupidly tried to secure it better. Upon failing that I loosened it a bit and I saw metal shavings begin to come off, and then an entire chunk of the casing - a little less than a quarter of the entire circle - chip off the crankcase. Upon this I realized something truly terrible has just happened, and my planned rides upstate - let alone the enjoyment of my first moto after my first oil change are off possibly indefinitely...

And that is how I discovered these forums. Hi everyone.

My bike is parked outside, and currently the drain plug is inside - there is no problem with the threading - its not stripped. The plug is holding easily inside however there is a very slow oil drip going into a bucket placed underneath.

My question is - Should I go the route of Kaseman - in this case draining all the oil, cleaning the surface, JB welding the little piece back in, and creating a piggy back plug with an allen bolt?

Today I will drain all the oil from the bike and let it all air out. I will also call all the local bike shops (Brooklyn, NY) and will consult with them regarding my newfound knowledge from these forums. My main problem is that I dont have a a garage space to carry a repair like that, so this will be an additional challenge. I will then take all the pictures and post them up on this forum.

Thank you guys for reading!

Last edited by klr4evr; 04-11-2014 at 09:19 AM. Reason: Edited to include URL's
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post #2 of 32 Old 04-11-2014, 09:38 AM
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Welcome to the forum. Sorry to hear about your dilemma but you should be able to get some good advice and get it fixed.

First thing you need to do is drain the oil and clean up the area to determine the extent of the damage. Take some pictures, post them on a photo sharing site (Photobucket) and PM me the links. I will add them to your post.

Dr. Damocles will be by shortly with his recommendation of an oversize drain plug. That would probably be the best solution but again pictures will help a great deal to determine the right approach.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #3 of 32 Old 04-11-2014, 11:30 AM
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Any way you can tap new treads?
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post #4 of 32 Old 04-11-2014, 11:35 AM
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If you have a crack near the hole depending on what the material is made out of...metals it can be welded "like new"
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post #5 of 32 Old 04-11-2014, 12:43 PM Thread Starter
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Draining the oil right now... When it drys up a bit I will take pictures and post. For now I looked inside the casing and it looks like not only did a piece on the external side of the casing is off, but also as though something might have broken deeper inside and fell off INSIDE... very scared right now... pictures coming up.
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post #6 of 32 Old 04-11-2014, 12:55 PM
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Stirletz,
It has been my experience that Forgetting The Drain Plug Gasket is the Cause of a Lot of these Cracks. Most usually, when forgotten on Aftermarket magnetic drain plugs.
Seems that the Last Thread and a Half are Not cut as Completely as the OEM drain plug.

The OEM drain plug will usually only have a Half thread un-cut, and only slightly damage only a half of a thread. And will be oil tight when screwed in with-out the Gasket, or just a slight 'weepage', but No Cracking of the crankcase.

One riding partner of mine, Cracked it, Stripped it and then, THROWED the broken chunk into the weeds!

I stuck a small natural cork in the drain hole.
Then, I was able to layer by layer, build-up the missing area, (sanding or roughing between layers), careful re-profiling of the gasket surface.
Then re-tapped for Over-Size 14mm X 1.5mm thread, automotive drain plug, with rubber faced steel gasket. (same tap as used to install 12 X 1.5 heli-coil)

Took about 5 hours, actual work time, spread over 3 DAYS.

pdwestman
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post #7 of 32 Old 04-11-2014, 02:07 PM
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Stirletz: Welcome to our little corner of the Net, the home of the world's most dedicated KLR 650 owners.

Reading is fun, but being involved is way better! Make us your online KLR 650 source.

Share your views, spread the word and bring your friends.

Looking forward to seeing pictures of your KLR. You'll be able to show it off once you have 15 forum posts behind you.

Enjoy.


PS - If you haven't done so already please fill in your Location in the User CP under Edit Your Details.

.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #8 of 32 Old 04-11-2014, 02:47 PM Thread Starter
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Thank You.

got the pictures ready, but perhaps I can email them to you? It would be a simpler. If not, no problem ill get to work on reactivating my Photobucket account.
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post #9 of 32 Old 04-11-2014, 04:57 PM
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Just post 13 more posts to upload pics. Thats what i did
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post #10 of 32 Old 04-11-2014, 06:11 PM
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Welcome to the site, you will definitely get the help you need.
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