Wilsons Sandbox

Posted: **Sun May 07, 2000 8:56 pm**

----- Original Message ----- From: Curtis Ling To: DSN_klr650@egroups.com> Sent: Sunday, May 07, 2000 9:49 PM Subject: [DSN_klr650] Bone-head confessions > > In my first ever attempt to change the oil and filter on any > motorcycle, I managed to break off the head of one of the nuts > securing the oil filter cover while tightening it. ("Tighten it until > you hear something crack, then back off half a turn.") After > recovering somewhat from the psychological pain and abject > humiliation, I decided to leave my KLR empty of oil and consult this > group for advice (thereby making my humiliation public). I have the > following questions: > > 1) How realistic and easy would it be to extract the broken nut > myself? If so, how should I best proceed with this? (Suspend your > disbelief and ignore my pathetic moto-mechanics track record for the > moment.) > > 2) If not, is it safe to fill my KLR with oil and ride it with only > one oil filter cover-securing nut to my dealer (less than 15 miles > away) to get this mess sorted out? > > I'm still feeling pain right now so please be gentle with me. > > -Curtis 1) Have you tried taking the other screw out, maybe you can get the cover off, and remove the broke screw with needlenose pliers. Just a thought. 2) Dont ride it if it's leaking oil!! You can get it out. You'll have to find a replacment screw though. Mark Wilson http://www.geocities.com/motormark64/ http://www.angelfire.com/mo/motormark/ KLR-650 A-13 "warthogg" XR250R "superfly" Stone Mountain, Ga ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

Posted: **Sun May 07, 2000 8:58 pm**

I'd try to use one of those reverse thread extractors first. But be real careful when you're drilling the hole in the busted off screw that you don't cut into the surrounding threads. If you succeed, it will partially make up for you're screw up, which BTW sounds like something I would do. -Dave http://www.city-net.com/~davekle/ Curtis Ling wrote:

> > In my first ever attempt to change the oil and filter on any > motorcycle, I managed to break off the head of one of the nuts > securing the oil filter cover while tightening it. ("Tighten it until > you hear something crack, then back off half a turn.") After > recovering somewhat from the psychological pain and abject > humiliation, I decided to leave my KLR empty of oil and consult this > group for advice (thereby making my humiliation public). I have the > following questions: > > 1) How realistic and easy would it be to extract the broken nut > myself? If so, how should I best proceed with this? (Suspend your > disbelief and ignore my pathetic moto-mechanics track record for the > moment.) > > 2) If not, is it safe to fill my KLR with oil and ride it with only > one oil filter cover-securing nut to my dealer (less than 15 miles > away) to get this mess sorted out? > > I'm still feeling pain right now so please be gentle with me. > > -Curtis > > ------------------------------------------------------------------------ > You have a voice mail message waiting for you at iHello.com: > http://click.egroups.com/1/3555/5/_/911801/_/957750586/ > ------------------------------------------------------------------------ > > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > Support Dual Sport News... dsneditor@... > Let's keep this list SPAM free! > > Visit our site at http://www.egroups.com/group/DSN_klr650 > To unsubscribe from this group, send an email to: > DSN_klr650-unsubscribe@egroups.com

Posted: **Sun May 07, 2000 11:40 pm**

> 1) How realistic and easy would it be to extract the broken nut > myself? If so, how should I best proceed with this? (Suspend your > disbelief and ignore my pathetic moto-mechanics track record for the > moment.)

is enough to find out...remove the other bolt/nut take off the cover and see if you have something to grab a hold of...if you do it will come out very easily as the source of the tension is now gone... Kurt

Posted: **Mon May 08, 2000 12:33 am**

On the off chance that the busted bolt doesn't come out easily, here is a trick that often will often free up a frozen bolt: Hit the bolt with light force one or more times (as if you were LIGHTLY driving a nail into wood). Don't use excessive force!! You're only trying to set up a cosmic shock wave to free the bolt. Some have theorized that the hammer blows "compress" the threads & free up the bolt. Whatever. I have used this trick many times over the years. One time I told a customer that it would cost $25 to remove his buggered up oil drain plug. He watched in amazement as I "tapped" on the drain plug several times & easily removed the frozen plug. He was upset at my charging so much money for such a quick repair. I told him that it was $1 to remove the plug & $24 for knowing HOW to remove the plug. Professor Federal Way, Wa. [USA] ps: I didn't collect any $ from the customer, it was an instructional freebie. ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

> > 1) How realistic and easy would it be to extract the broken nut > > myself? If so, how should I best proceed with this? (Suspend your > > disbelief and ignore my pathetic moto-mechanics track record for > > the moment.) >--- "Kurt Simpson" wrote: > is enough to find out...remove the other bolt/nut take off the

cover and see if you have something to grab a hold of...if you do it will come out very easily as the source of the tension is now gone...

> > Kurt

Posted: **Mon May 08, 2000 12:55 am**

At 01:49 AM 5/8/00 +0000, Curtis Ling wrote:

>In my first ever attempt to change the oil and filter on any >motorcycle, I managed to break off the head of one of the nuts >securing the oil filter cover while tightening it. ("Tighten it until >you hear something crack, then back off half a turn.")

Hey, I did not put those instructions in the archive! But, to make you feel better, I did the exact same thing. Luckily, I had a Makita drill, (with a lovely variable speed clutch thingie) and my boyfriend at the time had some ez-outs (yes, I own a really nice drill and no bits). So I was able to use his ez-outs (or reverse threaded drill bits) to get the screw out. Since you just had it out and put it in, it's not really stuck. More a matter of getting something in it so you can screw it out. It requires a light touch with the trigger finger on the drill tho'. Have faith, stop trying to brute force stuff (yes, I know that's how that little head snapped off that poor little bolt. I did it myself, remember?), get the other screw and another vehicle and go to a Home Depot and find a replacement bolt -- they have reasonable duplicates -- 2 in a package for like $1.50. And realize that when you're tightening down that cover, the o-ring is making most of the seal. You need the metal lid to be flush against the engine body, but you don't need to use the bolts to bind the molecules.

>2) If not, is it safe to fill my KLR with oil and ride it with only >one oil filter cover-securing nut to my dealer (less than 15 miles >away) to get this mess sorted out?

Um. Depends on how fast the oil is leaking out. If you can get it to not lose more than 1 quart in that 15 miles, then sure, go for it. But don't take any turns too fast. You've probably spewed about a quart of oil onto your rear tire...

>I'm still feeling pain right now so please be gentle with me.

You can do it man! I have faith.

---o&>o--- Sarah Barwig sarah@...

Posted: **Mon May 08, 2000 7:49 am**

Dreas Nielsen wrote:

>> From: Verle Nelson [mailto:whimsy@...] >> > >> > Loosen the two Allen bolts at the rear of each end of the >> > swingarm > >> Now I'm confused! I know of no allen bolts involved in the >>chain >> adjustment process. > >The chain adjustment mechanism on the 600 is different from that >on the >650--the 600 has eccentric cam adjusters. > >Dreas >

Sorry! I somehow missed the KLR600 reference in the subject line. Eyes wide shut, I guess. Verle Nelson Cedaredge, CO

Posted: **Mon May 08, 2000 8:14 am**

Thanks for the fast response and ample advice. The bolt broke off below the opening (with the cover off) so I'm going to try the ez-out solution. I do have about a month's experience drilling and tapping (though you'd never know) and it's time to put it to good use, I suppose. -Curtis Mark Wilson wrote:

> > ----- Original Message ----- > From: Curtis Ling > To: DSN_klr650@egroups.com> > Sent: Sunday, May 07, 2000 9:49 PM > Subject: [DSN_klr650] Bone-head confessions > > > > > In my first ever attempt to change the oil and filter on any > > motorcycle, I managed to break off the head of one of the nuts > > securing the oil filter cover while tightening it. ("Tighten it until > > you hear something crack, then back off half a turn.") After > > recovering somewhat from the psychological pain and abject > > humiliation, I decided to leave my KLR empty of oil and consult this > > group for advice (thereby making my humiliation public). I have the > > following questions: > > > > 1) How realistic and easy would it be to extract the broken nut > > myself? If so, how should I best proceed with this? (Suspend your > > disbelief and ignore my pathetic moto-mechanics track record for the > > moment.) > > > > 2) If not, is it safe to fill my KLR with oil and ride it with only > > one oil filter cover-securing nut to my dealer (less than 15 miles > > away) to get this mess sorted out? > > > > I'm still feeling pain right now so please be gentle with me. > > > > -Curtis > > 1) Have you tried taking the other screw out, maybe you can get the cover > off, and remove the broke screw with needlenose pliers. Just a thought. > > 2) Dont ride it if it's leaking oil!! You can get it out. You'll have to > find a replacment screw though. > > Mark Wilson > http://www.geocities.com/motormark64/ > http://www.angelfire.com/mo/motormark/ > KLR-650 A-13 "warthogg" > XR250R "superfly" > Stone Mountain, Ga > ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

Wilsons Sandbox

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