Join Date: Nov 2009
Location: Lander, Wyoming
OK, Who forgot the gasket on the last oil change? (Just kidding, doesn't matter.)
I'll suggest / endorse J-B Weld Original slow curing epoxy and an oversize drain plug (14mm). From local auto parts stores.
Preparation and 100% Degreasing is the key to success here. Lean the bike to the right and triple clean the area!!!!!
Put a common cork in the hole! Use masking tape and J-B Weld to build up the broken area, may take several layers, roughing/re-contouring between layers.
Remove the cork, flatten the surface, slowly tap to larger size. I used an actual tap and an actual 14mm drain plug. Not my bike thankfully!
Sorry, I still can't do pics! Plan on taking 2 or 3 days, with curing time!
Welding usually burns the sealant out of the center seam of the cases. Can be re-sealed with J-B Weld smeared over the center seam. I've re-sealed a couple, after others welded and tapped!
Modify at "YOUR OWN RISK"!
Still riding my 1987 KL650-A1. 85,000+ miles & counting