Oil Leak At Crack In Drain Plug. - Kawasaki KLR 650 Forum
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post #1 of 34 Old 06-25-2012, 08:24 PM Thread Starter
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Oil Leak At Crack In Drain Plug.

Its a bad night in the garage tonight. I had a little drip following a high center move a week or so back. Tonight I drained the oil and guess what I found? Yep, cracked case. A nice hair line crack right up the threads on the front side of the plug. So the options I can think of are pull the motor and replace the section, have someone handy with a tig give it a go or.......I dont believe I am going to say this......JB Weld. What do you think my all knowing KLR friends? Much thanks in advance from a much bummed out KLR guy.
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post #2 of 34 Old 06-25-2012, 09:17 PM
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Any chance you could post a photo of the damaged area?



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post #3 of 34 Old 06-25-2012, 09:21 PM
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I'm not a fan of JB weld. If you try it you should probably grind out a scarf for the material to lie in. And it must be clean clean clean, before you apply the JB weld. I have not heard of anyone welding the cases. I don't see why it can't be done. I don't know if anyone knows what the case material is for sure, which would be essential information for a welder. You can always try the JB weld first and if it does not work then try welding. Good Luck.
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post #4 of 34 Old 06-25-2012, 09:37 PM Thread Starter
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Originally Posted by planalp View Post
Any chance you could post a photo of the damaged area?


I tried but when you pull the plug out and look at it you can really see no damage Eric. The crack runs from the flat surface the washer seats to strait up the housing through all the threads. The one picture I got that showed something just looked like a hair on the sealing surface. However when you put the plug in and torque it down it pulls the crack apart and the drip starts.
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post #5 of 34 Old 06-25-2012, 09:45 PM Thread Starter
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Originally Posted by CraigES View Post
I'm not a fan of JB weld. If you try it you should probably grind out a scarf for the material to lie in. And it must be clean clean clean, before you apply the JB weld. I have not heard of anyone welding the cases. I don't see why it can't be done. I don't know if anyone knows what the case material is for sure, which would be essential information for a welder. You can always try the JB weld first and if it does not work then try welding. Good Luck.
The case material is the big question. I am not a mig guy but if its not the right mix I would think it could be worse off?

I like you am not a JB guy. However I have over the years seen some stuff repaired with it that I said would never last. Two rerpairs that stick out are a stripped bolt on a Cat head and a broken mounting ear on a charge air cooler. Both repairs were done on the same vehicle and six years later its still running.
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post #6 of 34 Old 06-25-2012, 10:42 PM
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There was a good thread about a broken drain plug not to long ago, here's the link.

Like the others have mentioned a good welder is not going to attempt without knowing what the material is.

I'm a JB Weld guy myself. Prep is the key to getting a good repair. Use a solvent and clean all the oil and grease. Rough up the area with something like a wire wheel on a drill. Clean again. I would try to get the crack to expand a bit by putting in the plug and working some JB into it then pull the plug. Build up the area around the drain. Let it set 24 hours.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 06-25-2012 at 10:46 PM.
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post #7 of 34 Old 06-25-2012, 11:10 PM Thread Starter
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Originally Posted by Spec View Post
There was a good thread about a broken drain plug not to long ago, here's the link.

Like the others have mentioned a good welder is not going to attempt without knowing what the material is.

I'm a JB Weld guy myself. Prep is the key to getting a good repair. Use a solvent and clean all the oil and grease. Rough up the area with something like a wire wheel on a drill. Clean again. I would try to get the crack to expand a bit by putting in the plug and working some JB into it then pull the plug. Build up the area around the drain. Let it set 24 hours.
Spec I think you are on the right track here. OMG 8 pages of love on that other thread for sure. If somebody has more insite keep it coming. However I think I am going to go the JB Weld road and hope to get it patched up for the year and then use this as a reason to go 685 this winter and replace the case. All the best plans you know. I will update when I get it done. Much thanks guys, this is why this site is so great, good folks.
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post #8 of 34 Old 06-26-2012, 01:22 AM
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Perhaps you should consider "stop drilling" the crack first.
This is a common technique whereby a tiny hole is drilled at the furthest end of a crack, the idea being to stop it spreading further. I've never used JB Weld but I'm aware of the type of repair and agree that it could go for ever if you do a good job. If it was mine that's what I'd do and and then, being acutely conscious of the weakness there, would maybe use sealant or locktite or thread tape or a combination of all three whenever I changed the oil in future and then tighten it enough to seat nicely and no more. Perhaps lockwire the bolt if you are worried about it coming loose.
A few random thoughts.
iddy
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post #9 of 34 Old 06-26-2012, 04:34 AM
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Perhaps you should consider "stop drilling" the crack first.
Just curious, iddy; how would you plug the stop-drill hole???????????

As to case welding; I know of a successful incident; new KLR; cracked case on rock (BEHIND the stock bash plate); rider had it welded by a competent shop, no subsequent problems.

Without examining the instant crack under discussion, if it doesn't extend too far radially, looks like a re-bore and tap to a larger size might cure everything.

If only a slight radial excursion, an oversize drain plug might fix it, although I realize some forum members run, screaming, from the room at this prospect!
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post #10 of 34 Old 06-26-2012, 06:10 AM
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Question

Lonerider,
I figure that if the JB weld can permanently seal a crack, then it should
be good to plug a 1/16th hole.
iddy.
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