spotted 04 klr north carolina

[sergio de oliveira]

hi. A couple weeks ago, I broke the threaded part of the oil drain hole on my crankcase. My mechanic told me, it can't be welded, but we can try to put on a rubber expanding plug & with every oil change, replace it with a new one. Or a sealed steel sheet can be put on the case. (Otherwise, I will have to buy new crankcases.) This time I'm sending photos, so feel free to offer any other suggestions --------------------------------- Do you Yahoo!? Friends. Fun. Try the all-new Yahoo! Messenger [Non-text portions of this message have been removed]

[George Basinet]

Good morning. I installed one in my Peugeot and it lasted for years. The plug I used was rubber one with a removable bolt insert so that you could change the oil. I got it the local auto supply store. George Escondido, Ca

----- Original Message ----- From: "sergio de oliveira" To: DSN_klr650@yahoogroups.com> Sent: Thursday, June 10, 2004 8:34 AM Subject: [DSN_klr650] pics of broken crankcase > hi. A couple weeks ago, I broke the threaded part of the oil drain hole on my crankcase. > My mechanic told me, it can't be welded, but we can try to put on a rubber expanding plug & with every oil change, replace it with a new one. Or a sealed steel sheet can be put on the case. (Otherwise, I will have to buy new crankcases.) > This time I'm sending photos, so feel free to offer any other suggestions > > > > > > --------------------------------- > Do you Yahoo!? > Friends. Fun. Try the all-new Yahoo! Messenger > > [Non-text portions of this message have been removed] > > > > List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Unsubscribe by sending a blank message to: > DSN_klr650-unsubscribe@yahoogroups.com . > > > Yahoo! Groups Links > > > > >

[James L. Miller Jr.]

Why can't it be welded? I've seen parts of the KLR cases that have been welded. If you have to split the cases to do it, so what! What's cheaper, a new set of cases or the time it takes to split and weld them. If cast iron engine blocks can be welded, why can't a cast aluminum one be? I'm curious. millerized --- In DSN_klr650@yahoogroups.com, sergio de oliveira wrote:

> hi. A couple weeks ago, I broke the threaded part of the oil drain

hole on my crankcase.

> My mechanic told me, it can't be welded, but we can try to put on a

rubber expanding plug & with every oil change, replace it with a new one. Or a sealed steel sheet can be put on the case. (Otherwise, I will have to buy new crankcases.)

> This time I'm sending photos, so feel free to offer any other

suggestions

> > > > > > --------------------------------- > Do you Yahoo!? > Friends. Fun. Try the all-new Yahoo! Messenger > > [Non-text portions of this message have been removed]

[kdxkawboy@aol.com]

In a message dated 2004-06-10 8:39:31 AM Pacific Daylight Time, sergio750102000@... writes:

> > hi. A couple weeks ago, I broke the threaded part of the oil drain hole on > my crankcase. > My mechanic told me, it can't be welded, but we can try to put on a rubber > expanding plug &with every oil change, replace it with a new one. Or a sealed > steel sheet can be put on the case. (Otherwise, I will have to buy new > crankcases.) > This time I'm sending photos, so feel free to offer any other suggestions > >

Sergio, Did you post the pictures? I went looking but didn't see any. As long as the hole is still more or less round, an expanding rubber plug can be used. For year now they have become the norm for fixing stripped out oil pan drain plugs on cars. Ran one on a F150 for four years without any problems. Pat G'ville, Nv [Non-text portions of this message have been removed]

[dirtrooster2003]

I dont understand why it cant be welded either. I knocked a hole in in the left side case of my TTR 250 a couple of months ago and had it welded back. Better than new now. Take it to a welding shop and a good welder will know what to do. It takes a ver good welder and one that knows aluminum to get it done right but they are out their. The guy that did mine said it was more like brazing than welding. --- In DSN_klr650@yahoogroups.com, "James L. Miller Jr." wrote:

> Why can't it be welded? I've seen parts of the KLR cases that

have

> been welded. If you have to split the cases to do it, so what! > What's cheaper, a new set of cases or the time it takes to split

and

> weld them. If cast iron engine blocks can be welded, why can't a > cast aluminum one be? I'm curious. > > millerized > > > --- In DSN_klr650@yahoogroups.com, sergio de oliveira > wrote: > > hi. A couple weeks ago, I broke the threaded part of the oil

drain

> hole on my crankcase. > > My mechanic told me, it can't be welded, but we can try to put

on a

> rubber expanding plug & with every oil change, replace it with a

new

> one. Or a sealed steel sheet can be put on the case. (Otherwise,

I

> will have to buy new crankcases.) > > This time I'm sending photos, so feel free to offer any other > suggestions > > > > > > > > > > > > --------------------------------- > > Do you Yahoo!? > > Friends. Fun. Try the all-new Yahoo! Messenger > > > > [Non-text portions of this message have been removed]

[Judson D. Jones]

--- In DSN_klr650@yahoogroups.com, "George Basinet" wrote:

> Good morning. I installed one in my Peugeot and it lasted for years.

Lucky for you you are in California. Peugeots don't last for years in Minnesota.

[kdxkawboy@aol.com]

In a message dated 2004-06-11 11:09:11 AM Pacific Daylight Time, dirtrooster2003@... writes:

> > I dont understand why it cant be welded either. I knocked a hole in > in the left side case of my TTR 250 a couple of months ago and had > it welded back. Better than new now. Take it to a welding shop and > a good welder will know what to do. It takes a ver good welder and > one that knows aluminum to get it done right but they are out > their. The guy that did mine said it was more like brazing than > welding. > >

Sergio sent me copies of the damage photos and I've posted them in the pictures undre a folder named Sergio's Drain Plug - http://photos.groups.yahoo.com/group/dsn_klr650/lst?&.dir=/Sergio%27s+DrainPlug&.src=gr&.view=t& .url=http%3a//us.f1.yahoofs.com/groups/g_488385/Sergio%2527s%2bDrainPlug/plug1.jpg%3fbcDoFyvB ny9TDj8k&.cx=150&.cy=112&.type=u It is bad, but it doesn't look terminal. I can see a lot of weldors running away from something like this, but it doesn't look any worse than the crankshaft bearing race I popped out. Perhaps I was lucky in having a friend of the family who ran the shop department at a California JC, but he was able to weld things up and then machined in a new bearing race. Such a repair can be done, but you might need to be looking for those weldors that would be called artists by their peers. I've got a buddy who is a master at keeping rat bikes on the road. I showed him the pics and he gave me his stock answer, JB Weld will fix it. Pat G'ville, Nv [Non-text portions of this message have been removed]

[kdxkawboy@aol.com]

Sorry about that, the empty post was to contain this email I got from biggranger@... - I believe he meant to reply to the group instead of just to me ... I've fixed worse than this before. It might even be able to be fixed without splitting the case. I'd clean it up real good, put a long bolt in and fill in around the bolt (with TIG). Pull the bolt out and drill and tap for a helicoil by hand and clean the chips away very carefully (helps to coat everything in grease). Screw in a cap again and file the sealing surface flat. Presto, all fxed, and about 2 hours of labor. [Non-text portions of this message have been removed]

[Darren Clark]

I've fixed worse than this before. It might even be able to be fixed without splitting the case. I'd clean it up real good, put a long bolt in and fill in around the bolt (with TIG). Pull the bolt out and drill and tap for a helicoil by hand and clean the chips away very carefully (helps to coat everything in grease). Screw in a cap again and file the sealing surface flat. Presto, all fxed, and about 2 hours of labor. kdxkawboy@... wrote:

>In a message dated 2004-06-11 11:09:11 AM Pacific Daylight Time, >dirtrooster2003@... writes: > > > >>I dont understand why it cant be welded either. I knocked a hole in >>in the left side case of my TTR 250 a couple of months ago and had >>it welded back. Better than new now. Take it to a welding shop and >>a good welder will know what to do. It takes a ver good welder and >>one that knows aluminum to get it done right but they are out >>their. The guy that did mine said it was more like brazing than >>welding. >> >> >> >> > >Sergio sent me copies of the damage photos and I've posted them in the >pictures undre a folder named Sergio's Drain Plug - >http://photos.groups.yahoo.com/group/dsn_klr650/lst?&.dir=/Sergio%27s+DrainPlug&.src=gr&.view=t& >.url=http%3a//us.f1.yahoofs.com/groups/g_488385/Sergio%2527s%2bDrainPlug/plug1.jpg%3fbcDoFyvB >ny9TDj8k&.cx=150&.cy=112&.type=u > >It is bad, but it doesn't look terminal. I can see a lot of weldors running >away from something like this, but it doesn't look any worse than the >crankshaft bearing race I popped out. Perhaps I was lucky in having a friend of the >family who ran the shop department at a California JC, but he was able to weld >things up and then machined in a new bearing race. Such a repair can be done, >but you might need to be looking for those weldors that would be called artists >by their peers. > >I've got a buddy who is a master at keeping rat bikes on the road. I showed >him the pics and he gave me his stock answer, JB Weld will fix it. > >Pat >G'ville, Nv > > >[Non-text portions of this message have been removed] > > > >List sponsored by Dual Sport News at www.dualsportnews.com. List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html >Unsubscribe by sending a blank message to: >DSN_klr650-unsubscribe@yahoogroups.com . > > >Yahoo! Groups Links > > > > > > > >

[Non-text portions of this message have been removed]

[dirtrooster2003]

Saw an red klr on hwy 74 between laurinburg and rockingham today. wondering if anybody on group