Oil drain plug stripped - 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 31 Old 08-06-2018, 10:18 AM Thread Starter
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Oil drain plug stripped

Hey all,

New to the forum - looks like I canít post URLs yet, so I just put the Amazon descriptions below. I just bought a 2007 KLR 650 a week ago and been fixing issue as Iíve been finding them.

The latest is a stripped oil drain plug that appears to have been held in place by JB weld (or some other hard plastic-like substance). Iíve been able to remove all I saw from the drain hole and it looks like shiny metal now, albeit stripped threads. The plug catches on a few threads part way in but is loose when fully screwed in. Iíve been googling and searching the forums. Looks like I could either buy:
1 - 5 M12-1.50 Single Oversize Oil Drain Plugs With Gasket = $19
2 - Heli-Coil 554412 M12 X 1.5 Metric Kit = $55
3 - TIME-SERT M12 X 1.50 Metric Drain Plug Repair Kit = $106

Iím thinking I probably shouldnít waste my time with an oversized plug and just get the time-Sert kit. Question that hasnít been clear is if I tried the oversized plug, would the M12x1.5 time-Sert kit still be an option, or would I be needing the big Sert kit and a larger plug?

Also, are there low profile bolt options better than: ďAE Motosports KLR 650 Kawasaki Low Profile Magnetic Drain PlugĒ

Thank you
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post #2 of 31 Old 08-06-2018, 05:20 PM
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Time-sert it, don't bother with the oversized plug. You're going to have to tap it either way, may as well do the insert. I think Eagle Mike has a low pro drain bolt but he's unavailable for about a month; I'd go with the tusk one instead. People seem to like their stuff.

I don't think an insert will be an option if you tap the hole out to a larger size, but I'm not sure. You may as well do the smaller option and retain the original size bolt


edit: disregard my comment, see damocles' post below

Last edited by insan3guy; 08-07-2018 at 12:23 AM.
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post #3 of 31 Old 08-06-2018, 06:11 PM
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By all means, TRY the oversize oil drain plug FIRST!

If it works, you have a low-cost PERMANENT repair. I have myself experienced "miracle cures" with a tapered, self-tapping oversize oil drain plug.

If it DOESN'T work, then . . . you're no worse now than you were (except for a few dollars); you can then approach other strategies (inserts/drilling-and-tapping larger/welding/etc.).

From your description of the situation; sounds ideal for an oversize oil drain plug repair.

Good luck!

=========================

A small detail, of little significance given the low dollar amount involved: The price quoted for the oversize plug and gasket appears somewhat excessive to me. You might check with your local automotive parts and accessories stores for a lower-cost alternative. The, "1.5" pitch might be hard to locate; I think 1.25 is more common. Regardless, you do well to follow suit with OEM pitch for the replacement plug.
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Last edited by Damocles; 08-06-2018 at 06:17 PM.
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post #4 of 31 Old 08-07-2018, 07:34 AM Thread Starter
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Thanks for the feedback!
I had already ordered the time-Sert. The oversized bolt is pricey since I can only find it online in a pack of 5. If I can find a single bolt in the correct pitch, Iíll probably try that first. If it works, I can just return the time-Sert.
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post #5 of 31 Old 08-07-2018, 08:52 AM
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Oversized plug, correct size tap, boom. Done. Might wanna flush out the threading chips and fill it up with oil.

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #6 of 31 Old 08-07-2018, 09:40 AM
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Quote:
Originally Posted by shaky6 View Post
Oversized plug, correct size tap, boom. Done. Might wanna flush out the threading chips and fill it up with oil.
As soon as you get the tap started, pour in a qt of oil. That way as soon as you remove it the oil will flush out the chips. If you just pour in some oil after removing it depending on how it makes it's way and how fast, you may not get them all out. Oh and grease the tap up good so most of the chips stay stuck to it and come out with it as you remove it.
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post #7 of 31 Old 08-07-2018, 09:46 AM
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the tap is fluted. The oil will just pour out all over your hand

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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post #8 of 31 Old 08-07-2018, 09:53 AM
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Quote:
Originally Posted by shaky6 View Post
the tap is fluted. The oil will just pour out all over your hand
Not with the tap packed with wheel bearing grease...
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post #9 of 31 Old 08-07-2018, 02:41 PM
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We've had oil pan bolts going on what, A HUNDRED years now and they haven't figured out that the metal around the bolt is too damn soft on ALL cars and bikes EVER.
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post #10 of 31 Old 08-07-2018, 02:46 PM
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I'm sure there's a give and take with hardness/brittleness in the metallurgy. I dunno. Make an oil pan out of super hard cast iron and it'll 1. weight a ton and 2. crack with enough stress and heat cycle and bolt torque. I'm just throwing darts at a wall.

1986 Honda TLR 200 Reflex
2002 Ducati Monster 750S < -- For Sale
2005 Kawi KLR 650
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