I broke my oil pan at the plug thread

Hi,

I've been working on many things trying to get my bike working (this is my first bike), and I just added more work ;(

When I changed my oil, I added a rubber gasket (that came with the oil filter) to the oil pan plug before tightening... thinking I needed to compensate for the rubber, I over-tightened and literally broke off a piece of the oil pan -- over half the length of the plug, and about half the circumference... the plug is undamaged.


So what are my options now?
- Buy a new oil pan (and if so where would a buy one)?
- or could it be welded?
- something i haven't thought of?

Try eBay.
Steve

May be able to weld it as long as they can line up the threads or retap.
Ebay is your best bet for replacement

I could be wrong, but the 440 might not have an oil pan. I think the oil drain plug screws into the bottom half of the crankcase.

Be sure to use a torque wrench.

Unlike the larger KZ models, I don't think the KZ440 has an oil pan. I believe you have broken the crankcase! (See image below).

If you need to replace it you are going to need to totally tear apart the engine and buy a new crankcase, (probably top and bottom halves so they match, but I'm not positive about that), and that will not be an inexpensive task considering parts, gaskets, etc. involved. So welding is probably your going to be your best bet. I would take it to a machinist who does welding to see what he can do.

Do yourself a BIG favor and invest in a torque wrench calibrated in INCH pounds, and then use the torque specs in the Kawasaki Service Manual to ensure you don't strip or break other components. There are a number of "wrench whisperers" here who will say you don't need to use a torque wrench, but I think you have already proven that some of us, including me, really should use them. Ed

Thanks for all the helpful replies!

Yes I should buy a torque wrench, but I've never had issues on torque stuff on my car -- I always just read up first on approximate turns

Your picture is accurate and helpful -- my "oil pan" is in fact a crankcase.

About 2 spins of metal were stuck on the plug, so the thread will be damaged even if we are able to weld the piece(s) back in perfectly.

Paid about $650 for the bike, and it has other issues... I'm considering calling this a learning lesson, and just saving up and paying more for a working bike. Any ideas on recouping the loss on this bike? ...

I suppose i can keep it around and try to buy a similar model (and use it for parts)

Wrench whisperers. :lol: :lol: Having it welded and tapped would be the best way. Take the motor to the shop that does welding aluminum. A torque wrench wouldn't have helped in this case. A impact driver would.


Even with the venerable non phillips bits, one of these will be the only way to get the screws, bolts, etc out.
Steve

swest wrote: Wrench whisperers. :lol: :lol:

I must admit, I borrowed that phrase from Kirk (keconomos). When I read his post I fell on the floor laughing at that phrase. Ed

Made me smile. :whistle:
Steve

never mind.

650ed wrote:

swest wrote: Wrench whisperers. :lol: :lol:

I must admit, I borrowed that phrase from Kirk (keconomos). When I read his post I fell on the floor laughing at that phrase. Ed

There's a big difference between whispering and shouting at the bastard :laugh:

Yeah. Speaking of which, I think next time I wont use the rubber gasket/"washer"as there was no leak before I had the gasket the fact that it was a tad big made the tightening situation confusing.