Cracked crankcase cover...HELP!...

[mbabc]

Hey folks,
Seems I have a hairline crack in my clutch cover crankcase. I have a big trip coming up in a little over a week and need this fixed.
Being 9 on the east coast I can't call any parts dealers to check stock.

So, what are the odds one would be in stock??

I've spoken with my local mechanical guru's and JB Weld might have to get me by. I'm sure this is self inflicted installing an upgraded clutch basket but I do wonder about the over sized dowel issue I've read about tonight.

Any advice appreciated.

Mark B.

 

[RCinNC]

I'd feel safe with a JB Weld repair, provided it was done correctly. For something like a hairline crack in a clutch cover, I'd probably widen the crack from the inside of the cover with a rotary bit on a Dremel tool. I wouldn't grind all the way through, but I'd route a groove along the crack and then fill it with JB Weld to make a fillet. This gives the JB Weld more surface area to bond to.

I might also drill a small hole at each end of the hairline crack (not all the way through the metal). This would provide some strain relief to keep the crack from spreading.

They make a high temperature JB Weld; I'd probably opt for that over the regular stuff. I'd also stick with the JB Weld that comes in tubes, rather than the epoxy putty. The stuff in tubes takes longer to cure, but I think it provides a better bond. Make sure you clean the inside of the clutch cover thoroughly before you apply the JB Weld.

 

[mbabc]

Great. Really appreciate the info. Just bites with a 2 week, 5k trip a week + away. Could have been closer to D day so I'll deal with it.

Thanks.

Mark B

 

[snakebitten]

Verify you can't get one in time. If that's true, and having that crack is going to gnaw at you and dilute your fun, you can have mine.

Yea, I've done this before and all turned out just fine.
Also note I have plenty of motorcycles. You are not stranding me without a horse.

 

[mbabc]

Thanks snake. Appreciate the offer.
I'm sure I'll get this figured out in time. Busy day on the phone for me tomorrow.

Thanks again,
Mark B

 

[Checkswrecks]

Lay the bike on it's side with the clutch cover up to minimize oil contamination of your repair before it cures, sand along the crack with 80 grit sandpaper, to make sure the JB Weld has something to grab, wash the crack real well with MEK* from Home Depot or Lowes, wipe with a dry rag, repeat a couple of times, and put the JBWeld on thick. You ought to be fine.




* MEK is methyl ethyl ketone. It's REALLY bad for you, but nothing else easily available will clean oil away like it can. Use it outside and make SURE to use nitrile gloves (also Home Depot or Lowes) because it will rip the oil from your skin and is a trans-dermal (through the skin) hazard to internal organs.

 

[Checkswrecks]

Verify you can't get one in time. If that's true, and having that crack is going to gnaw at you and dilute your fun, you can have mine.

Yea, I've done this before and all turned out just fine.
Also note I have plenty of motorcycles. You are not stranding me without a horse.

Proud to call you a friend!

 

[limey]

Verify you can't get one in time. If that's true, and having that crack is going to gnaw at you and dilute your fun, you can have mine.

Yea, I've done this before and all turned out just fine.
Also note I have plenty of motorcycles. You are not stranding me without a horse.

You truly are and awesome person.

 

[mbabc]

Yes, Snakebitten.
Way above and beyond the norm. That's fantastic that you'd offer a stranger help like that. Been a member here quite awhile and you're the stuff of legend. Always enjoy your posts.

Mark B.

 

[Don in Lodi]

The alignment dowel issue was a length thing and it would have shown up long ago with an annoying steady weep of oil.

 

[EricV]

Should you need one, I have a new spare clutch cover gasket on hand. Could Priority Mail it if need be.

 

[Tony99]

Hey MBABC I am in Bowling Green Ky kinda close to you and if you can't get it fixed feel free to call me you could use mine. 270-392-5055

 

[blitz11]

For what it is worth, i bought my daughter a used KTM exc 200 from a friend, who had had the cylinder replated. The acid dip they did prior to plating ate through the aluminum casting, causing a coolant leak into the exhaust port. (the hottest part of cooling system.)

It took a while to find the hole, but I fixed it with JB weld. Basically coated the porous area, and put it back together. 7 years and 400 hours later, it's perfect.

Fixing a crack on a side cover will be just fine. To clean the oil from the cylinder, i used maxxium contact cleaner. way less dangerous than MEK, and it worked just fine in a pretty brutal environment.

 

[mbabc]

Thanks Eric & Tony, (and everyone!)

I have a gasket inbound and it's arriving Monday. The collective has decided the JB is the best plan of action at this time. The crack is on the top of the case and was easy to spot .

My mechanic / engineer buddies are supervising me on the job...

I'll report back.

Thanks again all.

Mark B.

 

[Xclimation]

How about a welder?

 

[RCinNC]

Just in case you want some reassurances of how JB Weld performs in extreme applications, here's a good example: https://www.youtube.com/watch?v=aVLoJe3JbFI&t=503s

 

[Juan]

Just to offer some comfort. My brother was on a very long trip with his Triumph sports tourer and had a fall. He cracked the cover and lost oil. Other than that, no serious damage. Couldn't find a new cover to replace the damaged one. He managed to get back home, travelling a couple of thousand kilometers with a cracked cover sealed with hard metal. The moral of the story - if you can't find a new cover you should be perfectly all right with a welded repair job, so long as you do a good weld!

 

[Dirt_Dad]

Yes, Snakebitten.
Way above and beyond the norm. That's fantastic that you'd offer a stranger help like that. Been a member here quite awhile and you're the stuff of legend. Always enjoy your posts.

Mark B.

That is just so Snake. I agree with Checkwrecks completely.


Mark - I cracked a crank case while taking a silt bath on my first day riding Baja. I saw a lot, but not all the oil leak out. The mechanic for the tour company took the bike that night, laid it down filled it with some type of putty (maybe JB Weld), sanded it down, then never thought about it again. I guess they considered it such a routine thing they didn't even charge me for damaging their bike.

 

[mbabc]

Thanks Jon.

My gasket arrives Monday and my adult supervision is coming over in the evening. Think I'll be good to go.

 

[Dirt_Dad]

Good to hear. Have a grate trip.