First oil change/disaster...test the warranty - 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.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 16 Old 09-13-2013, 07:47 AM Thread Starter
Neutral
 
Join Date: Sep 2013
Location: Central Arizona
Posts: 10
First oil change/disaster...test the warranty

So, i put 400 on the bike and am going on a nice long ride today. I go ride the bike around and warm the oil up, drop the plug and pull the fill cap.....the rear bolt on the filter housing doesn't feel right coming out and I knew what I was about to see....yep sure enough the threads are galled. I managed to clean them up but the threads in the case cover look like crap and surely won't last forever. Anyone had this trouble and how is Kawasaki with warranty?
TurtleBerdley is offline  
Sponsored Links
Advertisement
 
post #2 of 16 Old 09-13-2013, 08:21 AM
1st Gear
 
Join Date: Jun 2012
Location: Houston TX
Posts: 17
Bad Threads

I'd be surprised if the mfr considers it a warranty fix. The bolt might have been overtightened at the factory, but since you were the one to pull it, there is no proof either way.

If the dealer had done the filter change, they might have put in a helicoil while they were in the engine. Or they might have just buttoned things up without worrying about it. I'd guess the second one.

Either way, you need a helicoil to get things up to snuff. The kits are not too expensive, about $25 at amazon.

Good luck!
Gene KLR is offline  
post #3 of 16 Old 09-13-2013, 08:26 AM Thread Starter
Neutral
 
Join Date: Sep 2013
Location: Central Arizona
Posts: 10
Yeah, I'm sure they would have buttoned it up just like I did lol, I will put a helicoil in next oil change. I'm satisfied it's ok for the time being.
TurtleBerdley is offline  
 
post #4 of 16 Old 09-13-2013, 08:35 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,283
Quote:
Originally Posted by TurtleBerdley View Post
Yeah, I'm sure they would have buttoned it up just like I did lol, I will put a helicoil in next oil change. I'm satisfied it's ok for the time being.
Fear not; one bolt will hold the oil filter cover, and . . . the O-ring provides the seal, not the bolts or their tightness.

I'd consider boring and tapping the hole for a bigger bolt, although I suppose an insert would be more elegant.
Damocles is offline  
post #5 of 16 Old 09-13-2013, 02:34 PM
2nd Gear
 
Join Date: Sep 2009
Posts: 257
I wonder what is wrong with those idgets assembling these machines. I had a similiar issue with my sparkplug. '09' with about 9k miles and decided to remove the sparkplug just to have a look. And the damn thing was cross threaded the entire length of the screw hole. Once i got the plug out i got the vacuum with a small fuel line taped to the end and stuck it down inside the cylinder in hopes i could suck up any filings that may have dropped.
Luckily i didn't have to re-tap the plug hole and a new sparkplug threaded in no problem. But i know the idiot at the factory simply kept screwing the sparkplug in without removing it to see why it was binding (maybe that was a good thing).
Thats the kind of quality control you get from a country where the people are paid a whopping $1.50 aday.
Thanks for letting me use your post to vent alittle.
basement is offline  
post #6 of 16 Old 09-13-2013, 06:48 PM
1st Gear
 
Join Date: Sep 2012
Location: Annapolis, MD
Posts: 42
It was probably done with an air tool and the assembler never even noticed
longroute is offline  
post #7 of 16 Old 09-14-2013, 12:07 AM
OverDrive
 
Join Date: Jan 2011
Location: NW MO
Posts: 5,337
I would imagine in that situation if you're a factory worker and you know you've cross-threaded the bolt but also know you can just crank it on in and nobody will know the difference when it leaves your line, it's probably more tempting to go ahead and do that than to tell you boss you just screwed it up. Is it right to do so? No. Is it human nature? For a lot of people, yeah.



planalp is offline  
post #8 of 16 Old 10-18-2013, 10:06 PM
1st Gear
 
Join Date: Oct 2006
Location: Keaau, Hi. USA
Posts: 16
Bought a new 2001 KLR250 that year. A friend and I were staying at his cabin and riding to some trails I used to ride back in the 1970s. We were returning to his cabin (maybe a 20 mile street ride), when at 1357 miles my KLR developed a bad death knock. He rode his KLR250 to his cabin and brought back his trailer and we towed it home. Took it to the dealer. They found a small piece of silicone sealer from engine assembly had broke loose and plugged the oil supply to the top end. I was hoping for a new engine, but was told Kawasaki only repairs warranty problems, and never replaces engines. Even if the repair cost is higher. Got a new cylinder head, cams, rockers, cam chain tensioner, etc., etc.. Cylinder was all right. It was repaired well, though it took forever, as Kawasaki has the dealer do a partial tear down and then get corporates okay to continue on in stages.

IN owning about 25 motorcycles so far over 52 years of riding, that was the only Japanese bike I ever blew up. Did blow up an old BSA 500 twin, but then, that's what BSA's did best.

Jon in Keaau, Hawaii USA
birdmove is offline  
post #9 of 16 Old 10-18-2013, 10:42 PM Thread Starter
Neutral
 
Join Date: Sep 2013
Location: Central Arizona
Posts: 10
Well, good news. They replaced the whole right side cover assembly and in doing so I got a free oil change. I now have 2000 miles on the KLR and love it. Time for a new set of tires!
TurtleBerdley is offline  
post #10 of 16 Old 10-18-2013, 11:19 PM
1st Gear
 
Join Date: Oct 2006
Location: Keaau, Hi. USA
Posts: 16
Yu are replacing the tires after 2000 miles? I had a 2005 KLR650 (that I traded the KLR250 in on) and got about 12,000 miles off the original rear, and 13,000 off the front. That was all street miles though.

Jon in Keaau, Hawaii USA
birdmove 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
Second oil change Black knight 2008+ KLR650 Wrenching & Mod Questions 29 10-23-2012 05:27 AM
Synthetic Oil Change gaucho10 KLR & Other Motorcycle Related Discussion 10 08-23-2012 12:55 PM
How not to change oil CheapBassTurd How To's & Tech Guides 19 03-19-2010 01:07 PM
2009 First Oil Change SteelB12 2008+ KLR650 Wrenching & Mod Questions 4 03-30-2009 05:05 PM
oil change YANKEES6161 KLR & Other Motorcycle Related Discussion 13 11-03-2008 07:43 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