Just picked up a 2008 KLR day before yesterday. As always I went through it, new chain, new air filter, checked bolts at head pipe, changed oil and filter. Got the oil and filter exchanged, did notice that the drain plug was much tighter than I felt it should be when removing it.
Ready to button it back up, set my torque wrench for 16 lbs, started the bolt got it finger tight, put the wrench on and it just never tightened, almost felt like I put a 4Ē bolt in, just spun and spun. I realized right away it was not going to tighten and stopped.
I know there are some fixes, Iím thinking about just going up one size, or rethreading, but was hoping that someone who had this happen can weigh in.
I did put a bit of oil in to see how bad it would leak, but no leaks at all, of course Iíd never ride until it is remedied.
Sorry to here that! Many 3/8" & 1/2" drive torque wrenches are NOT accurate at those low of numbers.
Does your current drain plug have a 17mm hex head, about 3/8 inch tall & greenish in color? Did it have a 2mm thick aluminum gasket on it?
If so, that should be the oem drain plug. 12mm x 1.5mm thread pitch.
Heli-Coils do Not work well, because of how thin the RH portion of the drain boss is. It leaves too much of the Heli-Coil unsupported.
But here is an interesting tid-bit. The 12mm x 1.5 pitch Heli-coil Tap is Exactly the same as a 14mm x 1.5mm pitch tap
Once you tap the hole & see the amount of new threads, just purchase a 14mm x 1.5mm thread pitch automotive drain plug & gasket from a parts store.
Purchase as small of head size as they have, so you won't have to re-dress the flat step on the RH side of the drain boss. And one will be less inclined to over tighten in the thin/soft aluminum.
Just 'snug' on a 4 - 6 inch wrench is perfect.
The molecules of an aluminum gasket get 'tilted' like animal hair. They get a grip when pulled/petted backwards.
Look at this KLR650 crankcase, https://www.klrforum.com/1987-2007-w...rank-case.html