Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Thread: Drain Plug Casing, cracked. Piece fell off... KLR 650 2005 Reply to Thread
Title:
Message:
Trackback:
Send Trackbacks to (Separate multiple URLs with spaces) :
Post Icons
You may choose an icon for your message from the following list:
 

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










  Additional Options
Miscellaneous Options

  Topic Review (Newest First)
04-13-2014 03:24 PM
Stirletz Preparation will work, luck? I can use some too
04-13-2014 02:53 PM
pdwestman Stirletz,
I wish you Good luck.
04-13-2014 01:07 PM
Stirletz
Quote:
Originally Posted by steferf View Post
My post was under the assumption that you had someone willing to split your case for 400 dollars and weld it. 400 dollars for that seems low for labor on this, but then again maybe a professional can work fast...
Nope Stef, he is just offering to take the engine off, not to take it apart. Hehe, if he was offering to take it apart and put it back together, I would buy a new cas8ng and pay him without questions.
04-13-2014 05:35 AM
MacG
Quote:
Originally Posted by Stirletz View Post
Also some specific questions:
If I decide to get it welded, what kind of welder should I seek out?
You want an experienced TIG welder that has some background with aluminum. It would be MUCH easier to do with the engine out of the bike . +1 on drilling a hole at the end of the crack to stop it from traveling. Even after cleaning oil from the area the casting will still have oil in the pores so after starting the arc there will be a LOT of smoke,splattering etc. Flow air through the crankcase to remove any vapors from the cleaner. Even after this there may be a slight "poof" when the arc is struck. If he holds the arc a while it will burn the oil out and then he can then add filler rod. To keep from causing too much heat in the area I would weld in short sessions(about 3/8" or so) at a time and let it cool before doing another. If you go with a plug and smaller piggy back plug you may want to wait until after the welding to tap the hole in case there is some distortion from the welding. You will need a different plug than OEM as steel and aluminum don't weld together. My first KLR had a crack in the same area from a PO that didn't use a crush washer and torqued the plug too tight. The damage on mine wasn't as bad so I repaired it with the engine in the bike. As for the damaged original threads,I installed a steel threaded insert and secured it with thread sealant. There are several good ideas in this thread and different ways to repair the damage,this is just how I would do it and how I fixed mine. YMMV Several years later the bike was still doing fine the last I heard.
Hopefully you can get it repaired or replaced without too much expense and time involved.
04-13-2014 12:24 AM
Stirletz Unless you guys think I can take apart the bike, take apart the engine, myself in a reasonable amount of time and without buying a ton of new tools, and put i5 back together. Then I would agree that this would be the way to go.. since the advatage of having a whole case, untarnished by cracks and such is self evident.
04-13-2014 12:22 AM
steferf
Quote:
Originally Posted by Stirletz View Post
Thank you, I will definitely do it. Probably good to repost it there.
Try not to get lost in a trance at their splash page slideshow.

About 2 years of my life have been spent looking at those pictures.
04-13-2014 12:21 AM
steferf
Quote:
Originally Posted by Stirletz View Post
I dont think thats the case. It will require the dissasembly reassembly of an entire engine. Thats probably the worst solution to this. Since timewise and expansewise( paying someone to do it, because I have absolutelyknowledge to approach such a task) it will be a very long time and very expensive to hire someone for that. The threads of guys before me ruled this one out for these very reasons, so I am speaking from that information.
My post was under the assumption that you had someone willing to split your case for 400 dollars and weld it. 400 dollars for that seems low for labor on this, but then again maybe a professional can work fast...I donno.

Either way you should take solace in the fact that ebay has some deals on used stuff. New, that part is about $800.
04-13-2014 12:15 AM
Stirletz
Quote:
Originally Posted by steferf View Post
If you really want someone local, go to the website called advrider.

That is a HUGE website. There will be people around your area at that site. This site is smaller, so it is less likely.
Thank you, I will definitely do it. Probably good to repost it there.
04-13-2014 12:14 AM
Stirletz
Quote:
Originally Posted by pokyIDAHO6ft4 View Post
Very true buying a new one would definitly save alot of hassle and money
I dont think thats the case. It will require the dissasembly reassembly of an entire engine. Thats probably the worst solution to this. Since timewise and expansewise( paying someone to do it, because I have absolutelyknowledge to approach such a task) it will be a very long time and very expensive to hire someone for that. The threads of guys before me ruled this one out for these very reasons, so I am speaking from that information.
04-13-2014 12:02 AM
steferf
Quote:
Originally Posted by Stirletz View Post
Also, this probably belongs in the introductions, but I live in Brooklyn, NY guys, if anyone has area specific knowledge on this, that would be amazing.
If you really want someone local, go to the website called advrider.

That is a HUGE website. There will be people around your area at that site. This site is smaller, so it is less likely.
This thread has more than 10 replies. Click here to review the whole thread.

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

 
For the best viewing experience please update your browser to Google Chrome