Stripped Oil Pan - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 22 Old 09-10-2011, 06:29 AM Thread Starter
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Stripped Oil Pan

Hey Guys!

Call me a dork, but I stripped the oil pan out on my 09 KLR. I need to tap it out to rethread it and I have a few of questions for those who have don this before:

The standard thread is 12mm X 1.5 pitch. At AutoZone I found a 14mm tap, but it has a 1.25 pitch. Is it okay to change the pitch? Should I drill it out before tapping? After tapping it out, did you bother with the inserts or just put the bolt in?

How did you keep shavings from getting up into the reservoir? I've read to use greese - how much?

Any and all tips and tricks you may have would be greatly appreciated. I am hoping to get this done today (9/10) as there is a 9/11 tribute ride tomorrow here in Denver.

Thanks in advance for all of your help!
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post #2 of 22 Old 09-10-2011, 07:07 AM
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Bookem, my STRONG suggestion:

Buy yourself an OVERSIZE oil drain plug at your automobile parts and accessories store; I'd recommend an M12-1.5 OVERSIZE product for your application (retaining the original pitch exploits any possible remaining thread material).

The tapered, self-tapping threads and slightly larger diameter of an oversize oil drain plug can rehabilitate the hole for a lasting seal and fix for the problem.

An oversize oil drain plug costs only a few dollars, and--if it seals, you have a permanent repair.

If it does not seal, you're no worse off than when you started.

I've had MIRACLE CURES with oversize oil drain plugs, although the procedure seems controversial in the hearts and minds of some, who insist upon inserts, drilling-and-tapping, welding, or other techniques.

Simply threading an oversize oil drain plug (with appropriate washer, of course) into you case may solve all your problems; worth a try, IMHO.

I'll post a link to show the vast array of oversize and repair oil drain plugs available:

http://www.cgenterprises.com/drain_p...ize_repair.htm

Again, expect opposition from insert aficionados and others, but--in my experience, an oversize oil drain plug can work and seal indefinitely (don't overtorque THAT one, although both first and second oversizes are available).

Good luck; try it, you'll like it!

Last edited by LoneRider; 09-10-2011 at 07:10 AM.
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post #3 of 22 Old 09-10-2011, 08:20 AM
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Arcane vagaries of the Internet department:

Received notification of a post on this thread by a "mysterious stranger," but . . . when I punched up the thread, the post was not there.

Regardless, I repeat a reference this masked man included in his now-disappeared missive:

http://www.clipsandfasteners.com/M12...g_p/a20759.htm

May we learn someday, who was that masked man?

-------------------

Since I've made an additional post on this thread, I'll add a comment, pre-emptively addressing criticism I anticipate regarding oversize oil drain plugs: What do critics think the purpose of the design, manufacture, and marketing of oversize oil drain plugs might be? What is the basis of the oversize oil drain plug industry?

Could it be . . . repair of stripped oil drain plug holes? The existence of the industry suggests some possible merit in the approach, to me; YMMV!

Last edited by LoneRider; 09-10-2011 at 08:30 AM.
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post #4 of 22 Old 09-10-2011, 08:28 AM
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It was I. I seem to have trouble beginning a post and finishing a post without going to eat breakfast, answering phone calls, putting the dogs in, putting the dogs out....sometimes it takes me an hour to finish a post and get it posted to the thread. In the mean time, the question asked is more than adequately answered, and my late to the party post is redundant. So to contribute to good housekeeping, I am trying to weed out my own contributed redundancies. Or stay focused on posting, which seems unlikely.


EDIT: BTW, welcome to the forum Bookem!

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post #5 of 22 Old 09-10-2011, 09:02 AM
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With the above confession, I take the liberty of publishing the previously purloined post:
Quote:
http://www.clipsandfasteners.com/M12...g_p/a20759.htm
You might consider an M12 first oversized self tapping oil plug. You might have
to snoop a bit at auto parts store for the 1.5 thread pitch. Most will be a
little longer than the stock oil plug length. The sump is deep enough to handle
that.
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post #6 of 22 Old 09-10-2011, 03:05 PM
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Been there, done that. You got better advice than what I did. If you do tap it (I did), grease and be careful with the shavings is right on.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #7 of 22 Old 09-10-2011, 03:06 PM
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Oh, and I ran two quarts of hot oil through before filling her up cause I'm anal.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #8 of 22 Old 09-10-2011, 06:20 PM
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Advantages of the oversize oil drain plug include, no drilling, no tapping (other than the action of the self-tapping threads upon initial insertion), and--metal chips can be dispensed with generally by a dab of grease on the plug, wiped off after unscrewing following initial insertion.

Don't need a drill, tap, insert, or anything other than the oversize plug and a wrench.
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post #9 of 22 Old 09-10-2011, 06:32 PM
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Hey Bookem, so how did this dastardly deed happen? Over-tightening? Cross-thread upon installation? Removed drain plug when super hot? Help prevent others from making the same mistake and share the cause.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #10 of 22 Old 09-10-2011, 11:20 PM
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My guess is overtorqued. Mine was the victim of a faulty torque wrench and stupidity. That aluminum is SOFT.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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