Broke an oil filter housing bolt. Please help! - Kawasaki KLR 650 Forum
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post #1 of 7 Old 09-11-2010, 09:56 PM Thread Starter
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Broke an oil filter housing bolt. Please help!

Hi,

Just got a used 2009 KLR with 4K miles on it and thought that I would change the oil and oil filter. Completed the job and took for a ride and noticed a titch of oil dripping out of housing so of course thought that I should tighten it a bit. There is no torque value for these bolts in the owner's manual (have a Clymer's on the way) and obviously over tightened one and it broke leaving the body in the bored bolt housing on the engine manifold. Now what??? Bummed
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post #2 of 7 Old 09-12-2010, 01:04 AM
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Is the screw broken off below the surface? If so, you're going to need to drill the bolt, dead center with a small drill and then use an EZ-OUT to extract the screw.



If the screw is broken off right at the surface, or slightly above the surface, you can take a small chisel and lightly tap in a line across the top, and then use that line like a screwdriver, and just back the screw out..

If you have to drill the screw to get it out, take it easy and don't break the drill in the screw. Then you'll have a real job ahead of you.

Remember that the cover for the oil housing has an o-ring in the housing. All the fasteners do is hold the cover on the bike. They don't do any sealing, and don't need to be any tighter than needed so they don't fall out. (Now he tells you)

Good luck.. It's actually not a difficult job, since the screw will be loose in the hole. It's not bottomed out in the threads, and just needs to be turned back out.

Oh, and here's more info.
http://homerepair.about.com/od/inter..._extractor.htm
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post #3 of 7 Old 09-12-2010, 06:54 AM
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I've used EZ outs one too many times over the decades.

Makes ya start following torque values a little closer.
I used to tighten small bolts way too much..........

A few gray hairs and a torque wrench go a long way!

Space, don't be stingy with the Loctite on your KLR, they love each other.




Cheeeeeeeeeeeeeeeeeeeeeeeeap








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This is my son, with whom I am well pleased." ----God

Last edited by CheapBassTurd; 09-12-2010 at 06:58 AM.
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post #4 of 7 Old 09-12-2010, 09:09 AM
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Quote:
Originally Posted by Paper View Post

If the screw is broken off right at the surface, or slightly above the surface, you can take a small chisel and lightly tap in a line across the top, and then use that line like a screwdriver, and just back the screw out...

I try to turn the screw with the chisel until it's loose enough to get out with fingers.

To prevent snapping bolts use the appropriate size tool, i.e. 10mm and under 1/4" inch drive. Don't use 1/4" adapters with a 3/8" ratchet. The tools are smaller for smaller size bolts to "discourage" over torqueing.

Use Loctitie to keep the bolt in place not brute force.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #5 of 7 Old 09-12-2010, 10:37 AM
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Originally Posted by CheapBassTurd View Post



Wow. Post number 666. Creepy.
667 The neighbor of the beast..
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post #6 of 7 Old 09-12-2010, 11:36 AM
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There should not be any tension on that broken piece so you may be able to use a small pick or something with a good slender point to turn it out until you can get ahold of it.

Last edited by SLO-KLR; 09-13-2010 at 10:23 PM.
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post #7 of 7 Old 09-13-2010, 08:14 PM
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Quote:
Originally Posted by SpaceRacer View Post
Hi,

Just got a used 2009 KLR with 4K miles on it and thought that I would change the oil and oil filter. Completed the job and took for a ride and noticed a titch of oil dripping out of housing so of course thought that I should tighten it a bit. There is no torque value for these bolts in the owner's manual (have a Clymer's on the way) and obviously over tightened one and it broke leaving the body in the bored bolt housing on the engine manifold. Now what??? Bummed
SpaceRacer,
Any luck??
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