Repairing Dr650 Oil Pan Hole: A Step-By-Step Guide

If you've got a hole in your Suzuki DR650 oil pan, there are a few ways to fix it. One option is to use a product called Heli-Coil, which involves drilling out the hole to a specific larger size, tapping new threads, and installing the Heli-Coil. This method requires careful drilling and tapping to avoid introducing metal shavings into the engine. Another option is to use an epoxy like JB Weld to repair the hole. This method involves cleaning the area around the hole, applying the epoxy, and allowing it to cure fully. It's important to note that the use of epoxy may impact the resale value of the vehicle. Additionally, it's recommended to add a skid plate under the engine to protect the repair. In some cases, it may be necessary to disassemble the engine and seek the help of a professional welder to repair the hole, especially if there is a risk of loose pieces falling into the engine.

Clean the area with brake cleaner and a wire wheel

To repair a hole in your DR650 oil pan, you'll need to clean the area thoroughly before applying any epoxy or other repair material. Here's a detailed guide on how to clean the area with brake cleaner and a wire wheel:

• Start by spraying the area around the hole with brake cleaner. This will help to remove any oil, grease, or dirt that may be present. Make sure to wear protective gloves and eyewear during this process.
• Use a rag to wipe down the area. This will help to remove any excess fluid and loose debris, making the cleaning process more effective.
• Next, take your wire wheel and gently but firmly scrub the area around the hole. Focus on cleaning at least a 2-inch circle around the hole to ensure that the entire area is free of any contaminants. The wire wheel will help to remove any stubborn grease, rust, or debris that may be present.
• Once you've scrubbed the area with the wire wheel, spray it down again with brake cleaner. This step will ensure that any remaining residue is removed, providing a clean surface for the repair.
• As an optional final step, you can use a propane torch to lightly heat the area. This will burn off any remaining contaminants and ensure that the metal surface is completely clean. Just be cautious and avoid using chlorinated brake cleaner, as it can produce toxic fumes when exposed to an open flame.

By following these steps, you'll have a clean and prepared surface to work with when repairing the hole in your DR650 oil pan. Remember to work in a well-ventilated area and always prioritize your safety when handling chemicals and tools.

Scuff with sandpaper

To repair a hole in your DR650 oil pan, you can use a product called a Heli-Coil. This will require you to drill out the hole to a specific larger size, tap new threads, and install the Heli-Coil. However, this task requires careful drilling and tapping to avoid introducing metal shavings into the engine, so it might be best to consult a mechanic.

If you decide to attempt this repair yourself, you'll want to make sure you're wearing protective goggles and a dust mask, and are working in a well-ventilated area. Before you begin, you'll need to select the right sandpaper for the job. In this case, you'll want to use an aggressive sandpaper like 60-grit to scuff the oil pan.

Scuff sanding is the process of lightly sanding a surface to prepare it for primer, paint, and/or varnish. It helps to smooth out imperfections and give paint and varnish something to grip onto. When scuff sanding, it's important to use a fine grit and a light touch to avoid scratches.

• Choose a fine-grit sandpaper: For scuffing bare wood or another surface before priming, painting, or staining, use sandpaper between P120 and P150. If you're scuffing between coats of paint or sealer, choose something between P180 and P220.
• Consider other tools: For floors, use a buffer and sandpaper. For rounded curves, a sanding sponge will work better than a flat sheet of sandpaper. For tight corners, choose a sander with a pointed tip or a fine wire brush. Steel wool also comes in various grades and can be used instead of sandpaper.
• Fold or wrap the sandpaper: Cut the sandpaper into quarters and fold each quarter into thirds lengthwise for small items or corners. Wrap the sandpaper around a 1-inch (2.54-cm) wide dowel for concave curves. Attach sandpaper or a sanding block to a pole for walls.
• Mark up bare surfaces: Use a pencil to draw squiggles on the surface to be sanded. This will help you judge how much you've sanded.
• Lightly sand the surface: Use a light touch and work with the grain, not against it. Do no more than three passes on edges and corners.
• Clean the dust off your work: Use a dry paintbrush, tack cloth, or damp cloth to wipe away dust. For larger pieces, use a vacuum or air hose first, then wipe down with a tack cloth.
• Check for unsanded patches: Rub a sock over bare wood to feel for rough spots. Look at varnished pieces from an angle in a well-lit area to check for shiny spots.
• Re-sand and wipe clean again if needed: Bare wood should feel smooth, while primed or painted surfaces should look chalky, and varnished surfaces should look matte. Don't over-sand, especially if the surface is primed, painted, or varnished.

Apply JB Weld

JB Weld is a two-part epoxy adhesive that can be used to repair a hole in your DR650 oil pan. It is a strong, heat-resistant adhesive that can bond various surfaces, including metal, and can withstand temperatures up to 500 °F (260 °C) constantly and 600 °F (316 °C) for short periods.

To use JB Weld to repair your DR650 oil pan hole, follow these steps:

Step 1: Surface Preparation

Start by cleaning the area around the hole in your oil pan. Use a wire brush or sandpaper to remove any dirt, grease, or debris from the surface. Ensure the area is free of oil and other contaminants. You can use brake cleaner or similar products, but avoid using alcohol as it can degrade the bond. It is important to work in a well-ventilated area when using these products.

Step 2: Mixing JB Weld

JB Weld is a two-part product, consisting of a resin and a hardener. For the best results, squeeze equal amounts of both components onto a disposable mixing surface, such as a piece of cardboard or a plastic lid. Mix the two parts thoroughly with a wooden stick or a similar tool for about one minute, until you achieve a uniform colour and consistency.

Step 3: Applying JB Weld to the Oil Pan

Once you have mixed the JB Weld, apply it to the hole in your oil pan. Use a putty knife or a similar tool to spread the mixture evenly and ensure that it fills the hole completely. You can also use your gloved finger to smooth out the surface and ensure a proper application.

Step 4: Curing and Hardening

After applying JB Weld, allow it to cure and harden. The initial setting time is about 4-6 hours, during which the mixture will thicken and become a putty-like substance. However, for a full cure and maximum strength, it is best to let it sit undisturbed for up to 15 hours, especially if the ambient temperature is cooler. If you are in a warmer climate, the curing time may be shorter.

Step 5: Sanding and Painting (Optional)

Once the JB Weld has fully cured, you can sand, drill, machine, or paint the repaired area if desired. This step is optional but can help you achieve a smoother finish and improve the appearance of the repair.

By following these steps and allowing adequate curing time, you can effectively repair a hole in your DR650 oil pan using JB Weld. Remember to work in a well-ventilated area, wear gloves, and follow the safety instructions on the product packaging.

Use a vacuum to draw the JB Weld into the repair

To repair a hole in your DR650 oil pan using JB Weld, you can use a vacuum to draw the epoxy into the repair. This will ensure that the JB Weld gets into the crack or hole and creates a strong seal. Here is a step-by-step guide:

• Drain the engine oil and ensure the oil pan is completely empty.
• Clean the oil pan thoroughly with brake cleaner or acetone. Spray it down and let it sit for a day, then spray it again.
• Use a wire wheel to clean at least a 2-inch circle around the repair area, then scuff with aggressive sandpaper (around 60 grit).
• Spray the area again with brake cleaner.
• Use a propane torch to lightly heat the repair area. This will burn off any remaining contaminants.
• Prepare the JB Weld epoxy by mixing it according to the instructions.
• Attach a shop vacuum to the oil filler. This will create a vacuum over the hole and draw the JB Weld into the repair.
• Apply the JB Weld to the hole and let it cure for the maximum recommended time in optimal conditions. Avoid extreme temperatures, high humidity, or other factors that could affect the curing process.
• Once cured, you can sand or scrape down any excess JB Weld to create a smooth surface.
• If desired, apply a coat of satin black paint to the repaired area and drive the vehicle on a dusty road to make the repair less noticeable.

This method of using a vacuum to draw the JB Weld into the repair has been used successfully by others to fix oil pan leaks and should provide a durable solution.

Add a skid plate to protect the repair

Skid plates are a crucial addition to your vehicle if you want to protect the undercarriage from damage. They are especially important if you plan to take your vehicle off-road, where the underbody is exposed to rocks, bumps, and uneven patches.

In the case of your DR650, a skid plate will not only protect the oil pan repair but also the transfer case, gas tank, and exhaust system.

Skid plates are typically made of metal or plastic. Metal skid plates are more durable and offer better protection, but plastic skid plates are also an option if you primarily drive on paved roads. Metal skid plates are usually made of steel or aluminum, with steel being the more popular choice due to its increased strength and resistance.

When choosing a skid plate, consider the following advantages of metal skid plates:

• Increased resistance to impacts and debris
• Protection for the front compartment of the car, keeping the engine shielded from dust and dirt
• Longer lifespan compared to plastic or fiberglass skid plates

You can purchase skid plates from automotive stores or online retailers, with prices starting at around $50 for a basic engine cover.

To ensure the skid plate provides adequate protection for your oil pan repair, consider the following:

• Inspect the skid plate regularly for any signs of damage or wear.
• Clean the skid plate periodically to remove any mud or debris that may have built up. You can do this by power washing it or using a fan-type sprinkler.
• If you feel any vibration or hear unusual sounds while driving, it could indicate that the skid plate is loose or damaged and needs to be inspected.

By adding a skid plate to your DR650, you can have peace of mind knowing that your vehicle is protected from potential damage, and you can enjoy your off-road adventures without worrying about your oil pan repair.

Frequently asked questions