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FAQ: DRZ400 Cracked Crankcase or Drain Plug

Question My son may have cracked his crankcase when he over tightened the drain plug after doing an oil change on his drz400 what do you recommend that he do to correct this problem? – Gary C. Answer Hi Gary, Let me try to provide you with as much information as I can. If the […]

Question

My son may have cracked his crankcase when he over tightened the drain plug after doing an oil change on his drz400 what do you recommend that he do to correct this problem? – Gary C.

Answer

Hi Gary,

Let me try to provide you with as much information as I can.

If the crack is bad you may need to split the case and replace the side with the drain plug. If you do this you’ll need to remove the engine and install new gaskets and bearings at the same time. This can be expensive but is also your best bet for a sure-fire fix.

If you are trying to fix it “on the cheap” here are some other options:

  • Completely seal (weld) up the drain plug hole and simply drain the oil through the frame plug.
  • If it is not leaking oil very badly and the crack is minor, a nice JB Weld job will likely suffice. Personally, I have used this stuff and it works very well. I just say “JB Weld” because it is what I’ve always called it!

Note: The crack probably came from over tightening the plug and the drain plug washer getting wedged into the case. Be sure to always use a fresh washer each time you remove the plug and make sure you put the washer on the drain plug correctly.

You can also refer to this thread for more information: https://www.thumpertalk.com/forum/showthread.php?t=667979

Best of luck,
John
DRZParts.com

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