Stripped Oil Drain Plug - 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 26 Old 03-08-2008, 05:43 PM Thread Starter
PTZ
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Stripped Oil Drain Plug

Well I did it. Stripped the damn oil drain plug but good on 06 KLR650. Dealer will put a Helicoil in for $60 if I can figure out how to get the bike there.

No one ever told me that if you leave your old manual adjusting torque wrench sitting around for a few months it will not release at the setting you selected like 16.5 lbs Good news to get out there and save someone else this grief.

Anyway, looking into Helicoils and I dont like what I have heard. Am now researching a product called "Full-Torque", Ford approved it for their repair shops.

Any ideas, suggestions etc that may or may not help?

PTZ
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post #2 of 26 Old 03-08-2008, 06:41 PM
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What about a tap that will cut new threads just a size bigger and use a slightly larger drain plug?

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 26 Old 03-08-2008, 06:45 PM Thread Starter
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Working on that right now. Great minds think alike. But,,,have you ever tried to find a 14mm x 1.5 x 15mm length shoulder Type 8 bolt with a tap to with it on a Saturday night? I am thinking of gunking the darn thing up with Blue Goo and hightailing it to the mechanic tomorrow. Just about given up. This is my Only mod of transportation!
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post #4 of 26 Old 03-08-2008, 08:39 PM
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First, I'd try to wrap it with a bunch of teflon plumbing tape to get to the dealer for the helicoil.

Another option might be to put it in place with JB weld and give it 24 hours to set. Mild heat helps. Then let the dealer bore it out for the helicoil. Since it's not really stressed, the helicoil should be fine.

Obviously, tapping for a new bolt would be the best fix. I'd buy several bolts and attach at least one spare to the bike.
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post #5 of 26 Old 03-09-2008, 11:25 AM Thread Starter
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I may have to try the teflon thing. I dont own a pickup, and my neighbor is in Minnisota for the next two weeks.

I am reduced to riding the bus to work. Ugh.
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post #6 of 26 Old 03-09-2008, 12:00 PM
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You can use silicone caulking as a temp heal.Use a solvent resistant high temp such as dow corning 736.It will hold your plug in and not leak.Make sure you don't over use it.Iwould try the teflon tape first like BIGIRON suggested.If it will hold the plug in till you get to your destination it would be easier to clean up.Good luck and keep us updated on how this turns out

Mike

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post #7 of 26 Old 03-09-2008, 12:08 PM Thread Starter
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A Quick Update to the Stripped Oil Drain Plug Saga

Got online instead of going to church this morning and found a site that specializes in magnetic oil drain plugs, all sized and flavors.
Ordered a couple of 14mm x 1.5 thread x 15mm long, with 13mm hex head.
Should be here Monday! Overnighting it and they were there in Sunday!
Almost identical to the orginal KLR bit. Except 2mm bigger. Enough to get by the thread and into new metal.
NOW I just have to find a tap! Seems that all tap sets in the universe only go up to 12mm. Any 14mm taps are designed for spark plug threads, different pitch?
Anybody got any line a 14mm x 1.5 pitch tap? At this point you can have my left axle nut for it!

Thanks!
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post #8 of 26 Old 03-09-2008, 12:16 PM Thread Starter
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By the way, heres the website for the magnetic drain plugs!
http://cgenterprises.com/magneticdrainplugs
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post #9 of 26 Old 03-09-2008, 01:33 PM
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Here is a link for your Tap:
http://www.victornet.com/cgi-bin/vic...ps:602,902,604

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #10 of 26 Old 03-09-2008, 02:01 PM Thread Starter
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Halfway There! (Do we ever really get all the way there?)

Thanks for link DXKLR!
I had been looking at another machine tooling site when your post came up! Again, Great Minds Stink Alike! The problem with my site was, they had minimum order amount and I was wandering around looking for things I may need next time I was repairing my 747!

This site, Victor Tooling in Brooklyn, NY is the Cats Meow! Very well organized no minimum, or at least, my order of $36 was greater! I have the tap, the drill, and the tap holder (Just in case, I recalled seeing one in the bottom of my tool box about 2 years ago) should be here by weeks end!

I will keep you all posted! thanks again for the suggestions and the help! I still havent heard from anyone whos done this. (Stripped out the oil drain plug ) Its good for the soul to confess!

Cheers!
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