Oil drain plug problem?? - 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.

 
LinkBack Thread Tools Display Modes
post #1 of 7 Old 02-18-2013, 11:06 PM Thread Starter
Neutral
 
Join Date: Feb 2013
Posts: 1
Oil drain plug problem??

Oil drain plug was stripped on my 08 klr 650. I read around on the forum and ordered a M12-1.50 oversized magnetic drain plug from cgenterprises. Well first off the drain plug is alittle more than a 1/4" longer than the stock drain plug. Will this be a problem, as long as nothing will hit it i should be good. I looked up there with a light and all looked well but im not a 100% sure. Second i guess i must of cracked the crankcase when installing the oversized drain plug ( even though i thought i did it right, wrench it in alittle than back off and clean any shavings intill it was all the way threaded in). Its a small hairline crack above the oil drain opening and it appears to leak slightly out of it. My 3rd problem is i think the plug might leak alittle as well, i even put alittle rtv around the washer but im not sure because the crack leaks and drips down off the plug. It seems to leak about a drop every 20-25 minutes when oil is warm and about 1 drop an hour when oil is cold. Should i even be worryed and how should a repair that hairline crack ( welding, apoxy, rtv ). Any help will be greatly appriciated.

Thanks,
Cody
cspaur is offline  
Sponsored Links
Advertisement
 
post #2 of 7 Old 02-19-2013, 05:33 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,415
Nice effort, cspaur!

You've staunched the flow to where the drip is more of an annoyance, than a catastrophic threat. Keeping an eye on the oil level, and a drip pan in the garage can keep you on the road.

(I assume you used a new crush washer and the leak is still present.)

If the case is cracked, chances are it cracked when the original plug was stripped, not upon insertion of the oversize plug, IMHO, because the slightly oversize diameter and self-tapping tapered threads aren't likely to split the hole. Then again, a pre-existing casting flaw may be there.

Next step? Might be able to drill-and-tap to a slightly larger size, although there's not much "meat" around the hole. Alternatively, cleaning up the area and J-B Weld (may need some release agent on the plug) could save the day.

Inserts (e.g., Timeserts or Helicoil, etc.) offer a permanent repair.

A rider I know cracked his case (Generation 2) and had it welded successfully; I'd imagine a shop that knows what it's doing could fix your bike similarly.

Best of luck, whatever additional solution you may seek; please let us know how it goes.
Damocles is online now  
post #3 of 7 Old 02-19-2013, 06:13 AM
1st Gear
 
hottrodd7's Avatar
 
Join Date: Nov 2012
Location: Brockport, NY
Posts: 60
Just a thought--how much for a new oil sump pan? Just replace the old one and be as good as new.

2009 KLR, 2008 Hayabusa, 2007 Interceptor, 2006 VTX 1300, 2012 Can-Am Spyder, 2004 RC 51
hottrodd7 is offline  
 
post #4 of 7 Old 02-19-2013, 06:46 AM
Lifetime Member
 
flash's Avatar
 
Join Date: May 2008
Location: North Texas
Posts: 1,534
Send a message via Yahoo to flash
Quote:
Originally Posted by hottrodd7 View Post
Just a thought--how much for a new oil sump pan? Just replace the old one and be as good as new.
Uhh, it's a vertically split case(s). No "pan".

Gray-haired riders donít get that way from pure luck.

Unknown
flash is offline  
post #5 of 7 Old 02-19-2013, 09:21 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,365
I'll make my usual recommendation of trying some JB Weld, first. What have you got to lose? As Damocles noted, don't "weld" the plug itself in place or get the stuff on the drain plug threads with the plug out. I would imagine some kind of grease or even Vaseline would serve as a release agent, anything to keep the JB Weld from sticking where you don't want it to stick.

I'd say it's a good sign your drip rates are so low and it won't take much to fill whatever gap is causing the seepage. Good luck!



planalp is online now  
post #6 of 7 Old 02-19-2013, 11:21 AM
2nd Gear
 
Join Date: May 2010
Location: Kansas City
Posts: 224
No Good

I feel your pain Cody. I had a problem like that just last year. I took a hit on the drainplug from a big rock and cracked my case at the drain plug. Long story short if the case is cracked the over sized drain plug is just going to open that crack up when tightened down. You have some uptions as far as Keenzerts or Time-serts and JB weld but success is a role of the dice. Those are solid wall inserts that will resist the spreading force when tightened. As far as the welding that can be a role of the dice also. I pulled my motor and took it to a guy that was good with Aluminum. Long story short he got my crack welded up all pretty. However because of the heat the cases now leak oil right next to where the crack was....I just cant win....Cases can be found for 150/200 bucks on e-bay, thats the route I will be going after this rididng season. My bike still drips a little oil but not enough that I have to add. If you can do that kind of labor yourself I think its the way, It is for me. Best of luck Cody
moriver is offline  
post #7 of 7 Old 02-19-2013, 12:38 PM
4th Gear
 
Spec's Avatar
 
Join Date: Apr 2010
Location: Gateway to Death Valley!
Posts: 1,928
Quote:
Originally Posted by cspaur View Post

...

My 3rd problem is i think the plug might leak alittle as well, i even put alittle rtv around the washer but im not sure because the crack leaks and drips down off the plug. It seems to leak about a drop every 20-25 minutes when oil is warm and about 1 drop an hour when oil is cold. Should i even be worryed and how should a repair that hairline crack ( welding, apoxy, rtv ). Any help will be greatly appriciated.

Thanks,
Cody

Hey just park next to a Harley, who's gonna know you left the drips!

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
Spec is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Oil Leak At Crack In Drain Plug. moriver 2008+ KLR650 Wrenching & Mod Questions 33 07-21-2019 06:23 PM
Magnetic drain plug? Savage 2008+ KLR650 Wrenching & Mod Questions 13 08-04-2013 09:16 AM
magnetic drain plug carlecamp 1987 to 2007 Wrenching & Mods 11 07-24-2010 03:11 PM
Stripped Oil Drain Plug PTZ 1987 to 2007 Wrenching & Mods 25 01-11-2009 03:48 PM
Lost oil drain plug at 65mph. BOSNM8 1987 to 2007 Wrenching & Mods 11 05-19-2008 01:07 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome