Join Date: May 2018
Location: Windsor, Ontario Canada
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.