KLR oil drain cracked/chipped housing question. - Kawasaki KLR 650 Forum
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post #1 of 15 Old 12-25-2018, 10:12 PM Thread Starter
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KLR oil drain cracked/chipped housing question.

So the oil drain bolt was over tightened, and this is the result after removing the bolt for the first time owning the bike to change the oil.... (REFER TO PICS). There are numerous threads on this very topic that can be found on KLRforum.com, but I still think that there are alternatives to: 1. welding the entire drain hole closed, and 2. JB Weld; though, I am not entirely sure what would work best and hold up for coming years. I want to keep this bike, and would really appreciate some of your opinions based on the damage described and shown in the pictures.



So, I just purchased my first KLR a few months back. It was an excellent deal, through a very close friend who was moving from the area. I never did my research on these bikes before I purchased this one, so I had no idea what to expect, other than quite a strong reputation. I knew that this bike (2004), was very well maintained throughout it's life. Before changing the oil, the bike never leaked oil, and was consuming oil according to specification. While pulling the bolt, I realized that it took a little more force than I was expecting, and a piece of the housing cracked off as you can see in the pictures. It's not horrible; there are still a good amount of threads where the bolt can thread back in, and it does thread back in without problems. There are also no hairline cracks around this area, and the case is otherwise clean.

However, there is the issue with the gap that is left when the bolt is re-threaded and the fact that it now has a slow leak from that spot. What are your suggestions? Have you encountered the same or similar problems? What were your steps in fixing the problem. I would really like to have it fixed for as cheap as possible. Really looking forward to hearing your responses and hoping to hear back soon! Merry Christmas, and a Happy New Year to everyone!

Last edited by klr4evr; 12-26-2018 at 12:54 PM. Reason: Fixed Tom’s link fix.
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post #2 of 15 Old 12-25-2018, 10:21 PM Thread Starter
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I cannot figure out how to attach pictures! Maybe someone can help me?
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post #3 of 15 Old 12-26-2018, 09:39 AM
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Originally Posted by Dooman92 View Post
I cannot figure out how to attach pictures! Maybe someone can help me?
I think you must attain 15 (or is it 10?) posts to put pictures on the forum.

I'm sending you my e-mail address by PM; you can send the files to me and I will post the images for you.

FAIR WARNING: I'm an advocate for the, "OVERSIZE DRAIN PLUG" solution, whenever possible (doesn't sound like it is in your case).
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post #4 of 15 Old 12-26-2018, 12:57 PM
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Quote:
Originally Posted by Dooman92 View Post
I cannot figure out how to attach pictures! Maybe someone can help me?
Forum rules require a 15 post count before pictures can be linked. Anti-spam feature. A Mod will usually fix that if the post requires it.

Welcome to the forum.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #5 of 15 Old 12-26-2018, 01:02 PM
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Most common reason that cases crack is lack of proper oil plug bolt washer. Do you have one? Are you using the stock plug or an aftermarket magnetic? I wonder if wrapping your drain plug with plumbers tape and or Teflon thread lube would stop your leaking.?.

@pdwestman will be along soon and Im sure he will offer you some good advice.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

This information makes it much easier for other members to answer/comment on your posts.
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post #6 of 15 Old 12-26-2018, 01:04 PM
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I'd FIRST try an oversize oil drain plug; will cost you $ 3.00 or so, and if it doesn't seal, you're still no worse off. Then, explore other options--drill-and-tap; insert; motorboat transom expandable drain plug; even . . . last ditch, WELD.
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post #7 of 15 Old 12-26-2018, 03:38 PM
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Quote:
Originally Posted by Dooman92 View Post
So the oil drain bolt was over tightened, and this is the result after removing the bolt for the first time owning the bike to change the oil.... (REFER TO PICS). There are numerous threads on this very topic that can be found on KLRforum.com, but I still think that there are alternatives to: 1. welding the entire drain hole closed, and 2. JB Weld; though, I am not entirely sure what would work best and hold up for coming years. I want to keep this bike, and would really appreciate some of your opinions based on the damage described and shown in the pictures.



So, I just purchased my first KLR a few months back. It was an excellent deal, through a very close friend who was moving from the area. I never did my research on these bikes before I purchased this one, so I had no idea what to expect, other than quite a strong reputation. I knew that this bike (2004), was very well maintained throughout it's life. Before changing the oil, the bike never leaked oil, and was consuming oil according to specification. While pulling the bolt, I realized that it took a little more force than I was expecting, and a piece of the housing cracked off as you can see in the pictures. It's not horrible; there are still a good amount of threads where the bolt can thread back in, and it does thread back in without problems. There are also no hairline cracks around this area, and the case is otherwise clean.

However, there is the issue with the gap that is left when the bolt is re-threaded and the fact that it now has a slow leak from that spot. What are your suggestions? Have you encountered the same or similar problems? What were your steps in fixing the problem. I would really like to have it fixed for as cheap as possible. Really looking forward to hearing your responses and hoping to hear back soon! Merry Christmas, and a Happy New Year to everyone!
If the oil drain plug was not leaking before you put a wrench on it, I'll suggest that you turned it the wrong way on your first attempt. Which started stripping the threads.
Then you probably dropped the gasket in the oil pan. Then the ill cut threads on an after market magnetic drain plug Fractured the boss when you reinstalled the plug, without the gasket.

Have you read my post #6 in this tread? JB Weld is your only cheap option IMHO & you need to have the patience to do it Yourself.
https://www.klrforum.com/1987-2007-w...50-2005-a.html


Quote:
Originally Posted by Damocles View Post
I think you must attain 15 (or is it 10?) posts to put pictures on the forum.

I'm sending you my e-mail address by PM; you can send the files to me and I will post the images for you.

FAIR WARNING: I'm an advocate for the, "OVERSIZE DRAIN PLUG" solution, whenever possible (doesn't sound like it is in your case).
Quote:
Originally Posted by Damocles View Post
I'd FIRST try an oversize oil drain plug; will cost you $ 3.00 or so, and if it doesn't seal, you're still no worse off. Then, explore other options--drill-and-tap; insert; motorboat transom expandable drain plug; even . . . last ditch, WELD.
Damocles, An oversized drain plug can not help until the gasket surface which is broken away is repaired in some manner.

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post #8 of 15 Old 12-26-2018, 05:35 PM
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@klr4evr,

Thanks for fixing the link.

We went out with the extended family for dinner. I had a Rob Roy, dry, with an olive before dinner. Then I had a Rusty Nail during dinner. After dinner I got a bit bored and tried to fix that link. On my phone.

Then dessert came...

Tom [email protected]

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post #9 of 15 Old 12-26-2018, 06:18 PM
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You mean to tell us that the TLW did not tell you to "put that phone down while at the dinner table."?

pdwestman
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Still riding my 1987 KL650-A1. 84,000+ miles & counting
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post #10 of 15 Old 12-26-2018, 08:04 PM
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Originally Posted by pdwestman View Post
Damocles, An oversized drain plug can not help until the gasket surface which is broken away is repaired in some manner.
Maybe not!

Then, . . . what about an expandable boat transom drain plug?
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