The dreaded cracked crankcase - Kawasaki KLR 650 Forum
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post #1 of 13 Old 10-31-2015, 03:51 PM Thread Starter
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The dreaded cracked crankcase

Hello all, a potential new KLR owner here


Here is my question I have a guy whom has a 2008 KLR 650 that runs with 18000 miles. He wants to trade for my 82 Honda GL500. Only problem he has an oil leak due to a crack near drain plug.

Is this too far gone to fix without having to "fix" it? I was thinking a piggyback plug?

TIA

I can send pics via PM

Last edited by YamaTexan; 10-31-2015 at 03:54 PM.
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post #2 of 13 Old 10-31-2015, 05:20 PM
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Every time I make this point, no matter when and where, somebody will come along and piss in my crackers.

I had a 2008 and now have a relatively early 2009.

I wouldn't trade a runt-of-the-litter piglet for a 2008 or 2009 KLR, especially one I wasn't really familiar with.

There are simply too many issues with the 2008 and 2009 KLRs, most especially oil burning. Add to that a cracked case and it just adds up to more thrills and entertainment than you deserve.

I've no idea what a GL500 is worth these days but, if it is Silver Wing in rather nice and restorable condition, I know I'd give more for it than I'd give for a 2008 KLR with a cracked case.

Never should have gotten rid of my '79 CX500; best bike ever. I'd rather see pictures of your Honda than the KLR...

Tom

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post #3 of 13 Old 10-31-2015, 05:22 PM
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Pretty common issue from over tightening the drain plug. Repair would really depend on how bad the crack is. Here are some threads on it if you haven't already checked them out.
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post #4 of 13 Old 10-31-2015, 06:22 PM
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If the crack is only a crack, not a missing chunk, it only needs to be 'degreased/cleaned, scruffed, re-cleaned, J-B Weld epoxied'!

Throw away the aftermarket magnetic drain plug with the Incomplete Final Thread which cracked it, when the last guy Forgot the thick aluminum crush gasket.

But like Tom suggest's, ya' might all ready own a less problematic bike! It just doesn't do dirt roads as well.

ps, I know that Tom S. really does want to see pics of the GL500!!
You can accidently slip him a damaged KLR pic.

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting

Last edited by pdwestman; 10-31-2015 at 06:30 PM. Reason: ps, added
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post #5 of 13 Old 10-31-2015, 06:44 PM
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NADA suggests values of,
GL500 Excellent Condition $3645---------GL500Interstate $3965
--------Very Good----------$2375----------------------------$2595
--------Good----------------$1535----------------------------$1710
--------Fair-----------------$1100-----------------------------$1210

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post #6 of 13 Old 10-31-2015, 07:11 PM Thread Starter
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I am very partial to dual sports which is the reason I am even considering it. I have never owned a KLR in particular. I have just stuck with XTs TTs and DTs.

I will mention that the guy says the plug is stripped and that he is scared to take it out to show me because he thinks he will never be able to get it back in.

Run and drives though so he says.

In the pic he sent me (and the one I can send you upon requests) it shows the drain plug with a crack just above it going away from it. Oil can be seen dripping from plug while seepage from the crack can also be seen.
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post #7 of 13 Old 10-31-2015, 07:12 PM Thread Starter
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And yeah my Honda is an Interstate. 1982 with 17K miles. No issues mechanically at all, can run all day long no sweat.
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post #8 of 13 Old 10-31-2015, 07:33 PM
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YamaTexan,
Have you read the links that 650stew provided?

We've provided this info many times previous.

Short course, Cracked, Stripped, Great!
Incomplete Thread, no gasket, broke/cracked it. Did not Know! Leaked. Tightened it more, leaked More! Tightened it MORE, Stripped it!
At least they did not break a chunk out of it and the chunk get thrown into the weeds! YET!

14 mm Oversize drain plug NAPA#704-1361, a NAPA#704-953 rubber faced Sealing Washer and J-B Weld, are your friends.
And some Patience, attention to Detail.

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #9 of 13 Old 10-31-2015, 07:40 PM Thread Starter
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I have not looked at one particular poster's posts on the matter. However, I have just about read over 50 threads (plus their pages). It seems the majority of the threads are dead threads that never really had that many pictures, or they did have pictures but a lot of the info was repeated. In most instances though it seems like the cracks to the drain plug are a different type of crack all together than mine. I am confident though in the JB weld approach with this particular issue though, but I thought some fresh reinforcement would be nice and help me in my decision to pull the trigger.

I certainly don't mean nor intend to beat a dead horse as far as the issue of having a cracked crankcase though.

Here's the crack:



Last edited by Tom Schmitz; 10-31-2015 at 08:42 PM.
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post #10 of 13 Old 11-01-2015, 06:45 AM
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One look will tell you this is NOT YamaTexan's GL; it's a CX on a gravel road somewhere in PA.


As nice as the CX was, I think dual-sports are superior in almost every way. Almost. I agree that an '08 with cracked case may be a significant project. But if there's a bike getting little use that may be a worthwhile project.

My CX cost $350 plus a couple stators and gaskets. My KLR was $1,200 for the first couple years then about that much again for piston, sleeve and machining. The KLR was worth it.
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