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post #1 of 30 Old 07-06-2010, 06:27 PM Thread Starter
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Need help ASAP.

Changing the oil. Filter cover bolts were TIGHT. I guess I overtorqued them. The left one is cracked clean through. I am debating JB quick weld or just putting it back on...and not tightening it too much like a fool. I know the O ring does the work anyway so I'm thinking this could be OK? Soliciting opinions. Bike is mid oil change right now.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

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AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
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post #2 of 30 Old 07-06-2010, 06:43 PM
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Help me a bit here, LJ. WHAT is cracked clear through...the filter cover? The bolt "wing" holes?
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post #3 of 30 Old 07-06-2010, 07:04 PM Thread Starter
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Yeah, the wing holes where the two securing bolts go into the filter cover (the left one). I just got the JB quick weld out. I think that's the best idea?

Upon further inspection, the area under the filter is not machined flat. I think I tightened it a little two much, but it definitely cracked along the ridge where the cover meets the bike.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #4 of 30 Old 07-06-2010, 07:09 PM
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Look it over real good for a way to reinforce the repair. I just looked at mine, and am drawing a blank on how to incorporate a way to reinforce the JB Weld without obstructing the bolt head. Best of luck.

EDIT: justing thinking out loud....I wonder if a washer the same outer diameter of the cover bolt, followed with a larger diameter washer would create a bridge to spread the pressure when you torque down the cover bolt?

Last edited by vatrader; 07-06-2010 at 07:13 PM. Reason: Added content
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post #5 of 30 Old 07-06-2010, 07:10 PM Thread Starter
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Not the best pic. Upside down, so it's on the right, but you can see the crack.






"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #6 of 30 Old 07-06-2010, 07:24 PM Thread Starter
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Quote:
Originally Posted by vatrader View Post
Look it over real good for a way to reinforce the repair. I just looked at mine, and am drawing a blank on how to incorporate a way to reinforce the JB Weld without obstructing the bolt head. Best of luck.

EDIT: justing thinking out loud....I wonder if a washer the same outer diameter of the cover bolt, followed with a larger diameter washer would create a bridge to spread the pressure when you torque down the cover bolt?
I thought about that, too. I don't know. I mean, there doesn't need to be a ton of pressure, just enough to hold the cap on...

And I don't know if trying to force JB weld into the crack is a good idea.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #7 of 30 Old 07-06-2010, 07:35 PM Thread Starter
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OK, I'm going to JB weld the crack (outside) VERY carefully and use a washer and hope.

I'm still trying to think of some way to incorporate duct tape and zip ties.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #8 of 30 Old 07-06-2010, 07:44 PM
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Ya, I would just use a washer on the bolt. Maybe you can find a smaller fender washer.

And stop eating your Wheaties before oil changes. Get a 1/4" drive torque wrench.

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post #9 of 30 Old 07-06-2010, 07:51 PM Thread Starter
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But wheaties are so tasty!

Just put a little JB weld on the crack and welded a washer onto the outside of the cover. Looks good. Well, it looks shitty. But I think it will work.

Thanks guys.

BTW, I was just looking online and it seems others have had this problem with the crack...check it out.

http://www.klr650.net/forums/showthread.php?p=163892




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
Lockjaw is offline  
post #10 of 30 Old 07-06-2010, 08:49 PM
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Looks like about $35.00 here http://www.kawasakipartshouse.net/pa...FQu0sgodqAxbxw

I know you have to be careful to tighten the cover bolts in sequence a little at a time to keep the cover from getting cocked and allowing too much pressure to be placed on one side or another until fully seated. Good luck.

Look up the fiche under "oil pump" P/N 11065

Gray-haired riders donít get that way from pure luck.

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Last edited by flash; 07-06-2010 at 08:51 PM.
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