Oh no stripped drain bolt - Page 2 - 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 #11 of 17 Old 07-29-2019, 02:13 PM Thread Starter
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Quote:
Originally Posted by PaddyD View Post
Easiest and cheapest fix ( until you decide to properly fix it) is go buy a 1/2" dia rubber expansion plug. I've seen them seal up sumps for YEARS with no problems.
I bought and tried the 1/2" expansion plug, unfortunately it does not fit. I'm not certain that it is not fixed. As of right now, some 15+ hours later, no leaks, and the bolt is torqued to 14lbs. I don't know if it gets any better than that.
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post #12 of 17 Old 07-29-2019, 02:22 PM
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Have a look at this. I suspect that your threads may be a bit compromised; I've never seen an aluminum tapped hole damaged a steel threaded fastener.

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post #13 of 17 Old 07-29-2019, 08:16 PM
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I am wondering if a previously installed Heli-Coil has stripped the Enlarged threads from the drain hole and now when the untrained eye looks at it, the threads "Look Good", but really do Not have a grip on anything?

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post #14 of 17 Old 07-29-2019, 09:13 PM
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If it was tapped for a Helicoil, then that thread would be an M14x1.5, wouldn't it? If that is true, the minor diameter of an M14x1.5 is about 12.4mm. A 12mm plug would pass in and out without catching on anything.

I'd like to know what the minor diameter of the current threaded hole is. If it is bigger than 10.4mm then it is stripped/stripping.

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post #15 of 17 Old 07-30-2019, 12:01 PM
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Quote:
Originally Posted by Niteryder View Post
I bought and tried the 1/2" expansion plug, unfortunately it does not fit. I'm not certain that it is not fixed. As of right now, some 15+ hours later, no leaks, and the bolt is torqued to 14lbs. I don't know if it gets any better than that.
well you'd need to carefully use a grinding wheel to slightly reduce the OD of the plug. Maybe a metric size could be found? I had one in an old Honda for about 5 yrs and the kid I sold it to had it in at least 3 more after that, so cheap as it sounds, it will work and work well until you have time/$$ to properly fix it.

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post #16 of 17 Old 07-31-2019, 05:42 PM
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perhaps I went overboard last year, but I've not had any further issues with mine after installing a time-sert

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post #17 of 17 Old 07-31-2019, 06:15 PM
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Caution: If you do choose to drill and re-tap to the next larger size plug make sure to drill and tap all the way through the casting because it is irregularly shaped on the inside of the case. If you don't thread through the entire case wall it will put stress on the oil plug bolt an could crack the thin casting wall. Here is a picture of the inside view of the drain hole so you can see what I mean. Best of luck.
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File Type: jpg oilplugresized.jpg (114.5 KB, 10 views)
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