Broken oil drain - 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.

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post #1 of 16 Old 05-14-2018, 02:57 PM Thread Starter
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Location: Windsor, Ontario Canada
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Broken oil drain

New to Forum, came across when I stripped and cracked casing around oil drain on KLR and was seeking information. Was very surprised to see how many members have experienced same problem. All of the input was very informative, so I decided to join Forum so I could share my experience and hopefully help others and give back to the Forum. I have some great pictures, but I am not allowed to attach images. Long story short, I stripped oil drain plug and chunked off some of the aluminum with the thread. The drain bolt would fall out of the hole because damage to threads was so bad. I brought bike to guy on Kijiji that had ad for welding aluminum as a side job from his full time welding job. He seemed very knowledgeable and said Kawasaki was known for poor aluminum casting. Anyhow, he laid the bike on it's side, cleaned and prepped damaged area, built the aluminum back up, smoothed surface and re-tapped with self tapping oversized 12mm drain plug tightened by hand, then wrenched a quarter turn using rubber gasket to help keep bolt from turning back. I dropped bike off on a Monday night, went to his place Wed night, put oil in bike, paid him $150 and rode her home. It's been 6 weeks,1000 km's and my OCD has me rubbing the oil drain plug with my finger every time I walk bike the bike. Not a drop. In regards to heat melting the gasket as I read from other posters, he said take breaks while welding so seals don't get hot enough to melt. That's my story, hope was helpful to someone.
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post #2 of 16 Old 05-14-2018, 02:59 PM Thread Starter
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Broken oil drain

Will get my 15 posts in so I can put some pictures up.
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post #3 of 16 Old 05-14-2018, 04:19 PM
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Good to know. Another reason for me to buy a welder
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post #4 of 16 Old 05-14-2018, 07:42 PM
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Aluminum welding is a whole lot trickier than steel, patroy75.

Good to hear that you found a better than average welder, Eddiezero. Most welded KLR oil drain repairs need epoxy over the center seam a few inches fore & aft of drain hole, from what I've seen & read on the web pages in the past 9 years.

There is absolutely nothing wrong with the aluminum used in the Kawasaki engine cases! The cause is owner Error! The case could use more support, forward and left of the hole.

pdwestman
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post #5 of 16 Old 05-14-2018, 08:10 PM
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I must disagree with the quality of the metal on the KLR!!! I have never seen threads as fragile! The frame, engine! I think they get their metal from the same place as Kazuma! I think they use Zamak!
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post #6 of 16 Old 05-14-2018, 08:28 PM Thread Starter
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oil drain

I know 100% my fault. I screwed up big time. Had bikes for 34 years, always done my own oil, tranny, primary depending on the bike. I have never used a torque wrench in my life, always gone by feel and never had an issue. I will never forget that Easter Sunday when I had massive brain fart and was sent into a panic when I saw what I had done. Don't wish that feeling on anyone. What made it worse is that I had the bike for a week, it's 2016 with 5000k so basically new. On Easter I took her for first ride to warm up for oil change. I was really digging the bike, then disaster. I was so freaked out I purchased used casings from 2012 the next day. Happy with my repairs, but will keep my new used casings in a box in the closet for a rainy day. As for the quality of aluminum I'm just saying what he told me. I love this bike, so wasn't going to argue with the guy that was fixing it for me. Not going to lose his #.
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post #7 of 16 Old 05-14-2018, 08:45 PM
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Quote:
Originally Posted by Eddiezero View Post
I know 100% my fault. I screwed up big time. Had bikes for 34 years, always done my own oil, tranny, primary depending on the bike. I have never used a torque wrench in my life, always gone by feel and never had an issue. I will never forget that Easter Sunday when I had massive brain fart and was sent into a panic when I saw what I had done. Don't wish that feeling on anyone. What made it worse is that I had the bike for a week, it's 2016 with 5000k so basically new. On Easter I took her for first ride to warm up for oil change. I was really digging the bike, then disaster. I was so freaked out I purchased used casings from 2012 the next day. Happy with my repairs, but will keep my new used casings in a box in the closet for a rainy day. As for the quality of aluminum I'm just saying what he told me. I love this bike, so wasn't going to argue with the guy that was fixing it for me. Not going to lose his #.
Could it be that previous owner got threads partly striped, and you just finished the job? I've had bolts that had been broken , but not in 2 pieces. All it took is a little more force to finish the break.

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post #8 of 16 Old 05-14-2018, 09:07 PM
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Eddiezero, you have made my day, with your quotation:

". . . re-tapped with self tapping oversized 12mm drain plug tightened by hand, then wrenched a quarter turn using rubber gasket to help keep bolt from turning back."

Why am I so delighted?

Inside website joke, but . . . I have sung the praises of oversized oil drain plugs, many times. Some forum members run, screaming, from the room at the mere MENTION of an oversize oil drain plug.

Glad you had a successful weld build-up and . . . application of an OVERSIZE OIL DRAIN PLUG!
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post #9 of 16 Old 05-15-2018, 10:29 AM
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Originally Posted by Hvymax View Post
I must disagree with the quality of the metal on the KLR!!! I have never seen threads as fragile! The frame, engine! I think they get their metal from the same place as Kazuma! I think they use Zamak!
I've owned 41 motorcycles to date; Kawasakis, Suzukis, Hondas, Yamahas, Betas, Gas-Gas', KTM's and even a Harley......the metal/threads on the KLR seem to me to be typical. There are definitely some specific items that are weak (i.e. footpeg nuts, Gen1 upper subframe bolts) and some that require care (i.e. valve cover bolts, engine drain plug, etc.) .....most of the problems that people experience are owner induced and many are coming from an automotive wrenching background with little/no motorcycle wrenching experience; these things do NOT respond well to the "tighter is better" mantra, unfortunately.

If you overtorque your fasteners on your Honda or other bike, they'll strip out easily too.

JMHO

Dave
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post #10 of 16 Old 05-15-2018, 11:00 AM Thread Starter
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Pictures to come. Just have to put 15 posts first.
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