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Thread: KLR oil drain cracked/chipped housing question. Reply to Thread
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  Topic Review (Newest First)
12-27-2018 07:43 PM
PaddyD Damocles, In addition to the adapt and overcome, you forgot the " Lead follow or get the fu#* out of the way! We got a war to fight!"

Besides, the drain isn't even under any pressure. I have seen them work for years on end as a field expedient repair. I've even seen them go for a couple years in a 350 Chevy block as a quick repair for a freeze plug when a dummy let his engine freeze cause he was too cheap to add anti-freeze to a leaky radiator and thought water was OK in the winter.. ( no that time it wasn't me)
12-27-2018 02:54 PM
PaddyD When I was 11 yrs old I did the same thing to my Honda 50 mini bike. After my dad beat the shit out of me for doing it he sent me down to the hardware store for a 1/2" rubber expansion plug. He pushed it in the hole, tightened the screw and it never leaked ever again. I rode that bike like that for years until I had more than outgrown it, Sold it to a neighbor kid who then continued to ride it that way for a # of years after that. Go on Amazon and search for a rubber expansion plug. I know from experience it will work and very cheaply too. Obviously, welding up the hole and machining a new seal surface would be optimal, but that would cost a major pile of cash..
12-27-2018 01:06 AM
Damocles
Quote:
Originally Posted by pdwestman View Post
Would you trust that suggestion on your personal bike?
Under emergency field expedient circumstances, with no better solution available, YES!

Just as I would REVERSE a worn-toothed sprocket in the field, with no replacement available ('til I could obtain a new one, of course)!

"Adapt, Improvise, and Overcome," as the US Marine Corps (and Clint Eastwood, in "Heartbreak Ridge") says! (I think MacGyver had a similar credo.)

12-26-2018 09:45 PM
Tom Schmitz
Quote:
Originally Posted by pdwestman View Post
You mean to tell us that the TLW did not tell you to "put that phone down while at the dinner table."?
No, she was busy talking about girly stuff.
12-26-2018 09:14 PM
pdwestman
Quote:
Originally Posted by Damocles View Post
Maybe not!

Then, . . . what about an expandable boat transom drain plug?
Would you trust that suggestion on your personal bike?



I thought that is what you would say!
12-26-2018 08:04 PM
Damocles
Quote:
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?
12-26-2018 06:18 PM
pdwestman You mean to tell us that the TLW did not tell you to "put that phone down while at the dinner table."?
12-26-2018 05:35 PM
Tom Schmitz @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...
12-26-2018 03:38 PM
pdwestman
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.
12-26-2018 01:04 PM
Damocles 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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