Damaged case with oil leak - Kawasaki KLR 650 Forum
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post #1 of 20 Old 02-13-2014, 11:22 PM Thread Starter
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Damaged case with oil leak

Looking for some ideas and confirmation. I already know how I'm going to try to fix it, just wondering if anyone else has a better (cheap) fix.

I was riding a couple of weeks ago and had just changed the front sprocket over to my 16T for the road trip. Now here's where stupid comes in.
I didn't get the C-clip on the master link all the way, and it came off on my way home after roughly 40 miles.
Well the chain took a good swipe at the case when it left the bike, and an oil leak started right after that. I thought it was the output shaft seal damaged in there and replaced that. No good, still leaks. Rode it tonight, leaked, and I cleaned it off with some brake cleaner. All nice and dry until I started it up.

That's when I could see oil seeping out of the oil galley tapered plug behind the sprocket.



I'm going to tap the taper plug and see if it moves, and reset it if I can get a clean shot at it, or replace it. Problem is, a good portion of the outside of the galley was shaved off.
Plan #2 is to TIG weld it right over the plug.



Comments, ideas, condemnations, and no, I've already ruled out JB weld.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #2 of 20 Old 02-14-2014, 12:41 AM
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TIG welding it wont work as they are dissimilar metals and you will only cause more heartache. I suggest drilling it with a left hand drill, Then you can TIG the case and retap the hole. Or you may be able to oversize the hole and go up to the next size pipe plug, that might get you into thicker meat on the case. Just be careful not to drill it too deep!

A KLR is not a motorcycle, it is a blank canvas with which to paint the rest of your life.
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post #3 of 20 Old 02-14-2014, 01:06 AM Thread Starter
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At first thought Jon, I was just going to lay a bead over the whole plug and bury it.
But I like the thought of putting an aluminum plug in there and setting a bead to it.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #4 of 20 Old 02-14-2014, 01:10 AM
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then why not just pull the plug and weld up the hole? Gotta be careful not to get the case too hot or you'll starting cooking the innards. Exotic metals TIG was my bread and butter for along time, I miss the challenge of odd jobs like yours.

A KLR is not a motorcycle, it is a blank canvas with which to paint the rest of your life.
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post #5 of 20 Old 02-14-2014, 02:37 AM
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Since the plug is tapered, a reset might seal . . . best of all possible outcomes, IMHO!

From the chain wax, looks like a new chain. Just put one on, myself; had choice of clip or riveted master link; clip was in the "too hard" box to install (without the special pliers for squeezing the plates together), so . . . I tried the riveted route.

Your post encourages me to check the peening of the master link pins (I'm not entirely confident of the adequacy of my handiwork); don't want my chain flailing the case as yours did, campfire!

Best wishes for an easy and effective cure.

If I had gone for the clip-style master link, I'd probably be making a similar post, since I couldn't perform a satisfactory installation/assembly
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post #6 of 20 Old 02-14-2014, 03:28 AM
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is the plug an 1/8 NPT or metric equivalent? Looks really small.

A KLR is not a motorcycle, it is a blank canvas with which to paint the rest of your life.
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post #7 of 20 Old 02-14-2014, 01:09 PM
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campfire,
I'll suggest staying away from the welding idea.
Permatex / Loc-Tite / J B weld are my good friends, for these issues.

Tilt bike to the right.
Clean area with brake cleaner and air hose 3 times.
Spray Permatex, Surface Prep on area. Allow to dry 3-5 minutes.
Add a drop or 2 of Permatex Penatrating Grade Threadlocker Green.
Allow to cure.

Or rough sand the area.
Brake clean and air hose area 3 times.
Permatex Cold Weld or J B Weld the area.

Or both!

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 20 Old 02-14-2014, 06:23 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
campfire,
I'll suggest staying away from the welding idea.
Permatex / Loc-Tite / J B weld are my good friends, for these issues.

Tilt bike to the right.
Clean area with brake cleaner and air hose 3 times.
Spray Permatex, Surface Prep on area. Allow to dry 3-5 minutes.
Add a drop or 2 of Permatex Penatrating Grade Threadlocker Green.
Allow to cure.

Or rough sand the area.
Brake clean and air hose area 3 times.
Permatex Cold Weld or J B Weld the area.

Or both!
Oh man does this sound like the voice of experience!
Thanks for the instructions, and I'll try that first. What's that worst that can happen? It leaks oil?
I am going to try to pick at that plug a bit and try to reseat it or maybe replace it with a larger size. I just don't want to put too much pressure on that out wall of the oil galley.
I'll go try to take a better picture of it, those were the iPhone camera.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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post #9 of 20 Old 02-14-2014, 07:03 PM
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Quote:
Originally Posted by pdwestman View Post
campfire,
I'll suggest staying away from the welding idea.
Permatex / Loc-Tite / J B weld are my good friends, for these issues.

Tilt bike to the right.
Clean area with brake cleaner and air hose 3 times.
Spray Permatex, Surface Prep on area. Allow to dry 3-5 minutes.
Add a drop or 2 of Permatex Penatrating Grade Threadlocker Green.
Allow to cure.

Or rough sand the area.
Brake clean and air hose area 3 times.
Permatex Cold Weld or J B Weld the area.

Or both!
That's the ticket!
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post #10 of 20 Old 02-14-2014, 07:21 PM Thread Starter
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UPDATE------------

Just went out and with a small punch and small ball peen hammer, tried tapping the plug in. it moved a little bit and then I started it up.
It has slowed down the leak to just weeping!


This after tapping the plug.



closer view---


And this is with the engine running. It was leaking enough before to "drip" every 20 seconds or so.


On to the sanding and sealant attempt.

Confidence is the feeling you have before you fully understand the situation."

Jeff in Napa California
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