Help! Drain Plug Broken.. - Kawasaki KLR 650 Forum
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post #1 of 81 Old 11-28-2011, 09:46 PM Thread Starter
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Question Help! Drain Plug Broken..

I need some help! Please! Tonight I decided to take the bike out and get it nice and warm then change the oil one last time before parking it for the winter. It was about 50 degrees outside. I drained all of the oil.. then was going to put the drain plug back in to 16-17 ft/lbs... when it got to about 5 ft/lbs, a couple of pieces fell of the engine! Now there is a big gap on the left (kickstand) side of the drain plug... Also, it wont even tighten up to 5 ft/lbs before slipping and spinning (as if it were stripped). I have never tightened it over 16 ft/lbs and unsure of how it could have broken! I did have issues recently with oil lightly leaking, and it could be that this piece was cracked... Does anyone have any ideas/advice on what I can do to fix this!? I am obviously not rich, so I am looking for any advise possible to fix this!? Thank you very much!!

I have attached some pics of the pieces, breakage, and gap (with drain plug tightened).

Attachment 1234

Attachment 1235

Attachment 1236

photo 4.JPG

Last edited by vinson1213; 05-24-2012 at 09:52 AM.
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post #2 of 81 Old 11-28-2011, 10:16 PM
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Oh thats not good. I can't think of anyway to "fix" that without fixing it. Maybe someone else will though. Were you using a crush washer with it?

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post #3 of 81 Old 11-28-2011, 10:32 PM Thread Starter
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Oh thats not good. I can't think of anyway to "fix" that without fixing it. Maybe someone else will though. Were you using a crush washer with it?
Yes, the crush washer was there. I think it actually hit something (high center) on one of my off-road riding trips this summer. Kinda in a loss for what to do..
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post #4 of 81 Old 11-28-2011, 10:42 PM
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http://www.klrforum.com/showthread.p...ped+drain+plug

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post #5 of 81 Old 11-28-2011, 10:44 PM
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I could see that. I've thought about getting a skid plate just for that reason. I bet you did pop it, cracked the case, seeped some oil, you finally broke it lose when reinstalling.

Maybe you could drain ALL the oil, clean it thoroughly, JB weld the pieces back on and Hope.

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post #6 of 81 Old 11-28-2011, 10:59 PM
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The JB Weld might work if you do a good job of degreasing. Short of welding-up the aluminum or patching the hole (by welding) and drilling a new drain hole, I'd make a thin steel sleeve (threaded outside to fit your existing drain hole, and inside to fit a smaller bolt) JB weld it in-place, and build up the outside with JB weld and fiberglass fibers. While you're building up the outside, insert your new drain bolt with a thin coat of grease on all surfaces. That will give the crush washer an even surface to seal against (of course, you'll need a smaller crush washer) and the grease will keep you from gluing your bolt in-place.

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post #7 of 81 Old 11-28-2011, 11:08 PM
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Yup, I say JB Weld and positive thinking. Sorry dude.




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post #8 of 81 Old 11-29-2011, 07:48 AM
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Quote:
Originally Posted by vinson1213 View Post
I need some help! Please!
This is my BEST EFFORT at offering you help, vinson1213!

The probability of success, if you follow my suggestions, is in the high 90 % range; if the solution offered does NOT work, you're no worse off (other than out single-digit dollars).

GET AN OVERSIZE OIL DRAIN PLUG, replace your stock plug with this component.

An oversize oil drain plug (M12 X 1.5) has the same pitch as the original, but . . . is slightly larger in diameter. The replacement part's tapered, self-tapping threads re-cuts the threads as it is screwed into the existing hole.

Use some care during initial insertion, maybe some "backing-and-filling," and--some grease on the new plug helps attract any metal shavings for removal, once the enlarged threads are cut.

Chances are your local auto parts and accessories store has oversize oil drain plugs in stock. Otherwise, an Internet search produces hits like this:

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

Doesn't work? You can then look into inserts, drilling-and-tapping for a larger size plug, welding, or whatever.

I have given you a low-cost, possibly permanent solution to your problem; if the oversize oil drain plug seals, it heals, in my book.

Stand by for posters who run, screaming, from the room at the mention of oversize oil drain plugs. Yet, one must wonder; how do the guys who work at the oversize oil drain plug factories ever make any sales, earn a livelihood, if their products are no good?

Good luck!

(Oh, and do NOT over-tighten the aftermarket plug, now! )
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post #9 of 81 Old 11-29-2011, 08:38 AM
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Lonerider,
Not bagging on your solution, but we put my father-in-laws 15-year-old dog to sleep last night and I could use a laugh. So I'm having one here:

"Stand by for posters who run, screaming, from the room at the mention of oversize oil drain plugs. Yet, one must wonder; how do the guys who work at the oversize oil drain plug factories ever make any sales, earn a livelihood, if their products are no good?" The same way cigarette manufactures and Ginsu knife makers do!

Okay, not really very funny but my threshold is pretty low this morning. If his threads were just stripped or crossthreaded I'd be right with you on this. I just don't see (from the pictures) how the crush washer will seat.
Regards
Mark

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post #10 of 81 Old 11-29-2011, 08:44 AM
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Normally that would work, but looking at pic #2 I don't know. No matter how far our you go it's still not going to seal flush.

You might take it by your local machine ship and see what they think. They've probably seen it all and can "fix" it.

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