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1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Thread: Oil drain plug stripped Reply to Thread
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  Topic Review (Newest First)
08-14-2018 10:13 AM
DPelletier Oversize plug is a good fix.....tapered, not so much IMO and the risk of splitting the case is high. 2 cents

Dave
08-12-2018 04:40 PM
Damocles
Quote:
Originally Posted by TryAgain View Post
As it turned out, mine was stripped with an oversized plug already.
FIRST oversize, or SECOND oversize?

Probably made no difference; however . . . oversize oil drain plugs actually come in different diameters, successively increasing.
08-12-2018 02:46 PM
TryAgain As it turned out, mine was stripped with an oversized plug already.
The rubber plug sounded like a good idea (especially as an emergency fix), but the insert and low profile drain plug looks more professional. 50 miles and a few days later.... not seeing any leaks! And have a few more tools in the toolbox...
08-11-2018 06:51 PM
Damocles
Quote:
Originally Posted by KLRCraig View Post

Point is... THAT 'RubberOilDrainBolt' solution has been around a good-long-while man! Looks like the pic from Damocles is different design, but I 'get' how it works and THAT it works.
True enough, KLRCraig!

The first rubber stopper of that design I saw, many, MANY years ago, was for soft drink bottles (yes, soft drinks once came in glass bottles). A metal toggle on the stopper expanded the rubber to seal in the precious carbonation (AIEEEEEE! The earth-threatening CO2!).

Later, I saw the same design of stopper used to close the drain hole in the transom of small boats (no, one didn't try to drain the boat this way while in the water!).

The latest plug picture posted on this thread appears of a similar design to the one you mention, KLRCraig, with a nut-and-bolt arrangement, versus a toggle, to expand the rubber circumference.

Thus, more than one way exists to seal a crankcase with stripped drain plug hole threads; some more MacGyveresque than others!
08-11-2018 06:13 PM
KLRCraig Back in about 1978 or so (I was 16YO) I offerred to help out my Sister by changing the Oil in her VW Dasher (POS).
The BRUTE that I was (quite the opposite, skinny rail) I over-torqued the OilPanBolt and stripped the threads BUT GOOD.
I thought I was in BIG trouble with Pop (and her) and then of course I had 'the issue at hand' that I KNEW meant I was 'F'd!!!'

Turns out Dad found a rubber stopper that you merely forced in the hole (with it's tool) and it expanded (kina like a toggle-bolt).
Life saved for $10...

Point is... THAT 'RubberOilDrainBolt' solution has been around a good-long-while man! Looks like the pic from Damocles is different design, but I 'get' how it works and THAT it works.

Great post to save here boysNgirls... could happen to any of us, even if we already read the KLRForum FAQs.
08-11-2018 07:45 AM
Damocles
Quote:
Originally Posted by PaddyD View Post
While this isn't the perfect fix, as long as you aren't dragging the engine over logs and rocks it will do the job just fine.
If it seals, it heals, IMHO!

As a public service, here's an image of the device featured in PaddyD's link posted above:

08-11-2018 03:38 AM
PaddyD While this isn't the perfect fix, as long as you aren't dragging the engine over logs and rocks it will do the job just fine.



08-10-2018 08:00 PM
Damocles For the rare few who may not have clicked onto the "Amazon" link in Post # 13 above, I offer this image in an effort intended for clarification:



Perhaps the considerations discussed in employing this part may be better understood. As some say, "A picture is worth . . . " (I forget the rest!)
08-10-2018 07:51 PM
pdwestman
Quote:
Originally Posted by PaddyD View Post
How would you stop at the 12mm diameter, short of the bolt head and still get it to seal?
To be perfectly honest PaddyD, I wouldn't use that Tapered plug on even a steel oil pan which the plug hole was facing to the rear, as in most automotive applications.

It is mostly like a National Pipe Thread plug, only longer & steeper.

But, I'm reasonably sure that it would 'seal mostly', if not completely, on most automotive applications. But it would also eventually have the oil drain hole enlarged to its Maximum Diameter within a dozen oil changes if left in the hands of the person which stripped out the original threads in the first place, by over-tightening IT, everytime!
08-10-2018 07:49 PM
Damocles
Quote:
Originally Posted by PaddyD View Post
How would you stop at the 12mm diameter, short of the bolt head and still get it to seal?
Good question!

I can think of two possibilities:

1. Since the plug is tapered, it will seal the hole at the 12 mm diameter penetration; this configuration would involve no gasket (outside of a very THICK one), however. And, as mentioned above, the plug would protrude considerably outside the crankcase were this arrangement followed.

2. The plug penetrates until the original hole is enlarged to 16 mm diameter as the plug is driven home; in this case, an ordinary (16 mm) washer would seem applicable. (This approach might lead to the catastrophe pdwestman suggests above as a possibility.)

DISCLAIMER: I do not know the answer; one might direct the question to the manufacturer, "Eco-plug," for a competent and qualified response.
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