Cracked crankcase cover...

I feel like a total champ...I bought a brand new right side crankcase cover and cracked it when I was bolting it on.

I have no idea how I did that as I was not really cranking the bolts. So aside from sourcing another one...can I repair this one with some JB Weld or something?

 

That sucks like a Hoover. Post a pic and lets see this crack.

 

Ok.. thanks Toe...I'm going now to my brother-in-law's where the machine is. I'll remove the cover and take a snap or 2 for you.

 

The pics are in my gallery...thanks again Toe!

 

I would JB Weld that sucker. Not a bad crack and you got noting to lose.

 

When you install that cover Boosh make sure the alignment dowels are lined up correctly and gently tap the cover with a small rubber mallet until it seats itself completely on the gasket,then install the mounting bolts.
If you drew the cover up to the engine case using the mounting bolts the first time you installed it that may have been the reason why you broke the cover. One of those dowels might have snagged on the cover and made it bind up.

 

Yeah.....what Stosh said.

 

Phuque me! : )

Well...I took the Dremel and roughed up the affected area and then some and now I'm letting Mr. JB Weld do his bidding.

 

Make me feel better...this is a common faux pas? non?

 

Yeah I suppose if you've never done it before that's prolly a very easy mistake to make Boosh. You definitely gotta know how to install those case covers correctly. While it's true that aluminum is a light weight and decorative metal,you always have to keep in mind that it's also a fairly soft metal as well.
As you found out the hard way,it won't take too much stress before it cracks.

You might also want to put a little bead of sealant on the cover gasket before you install that case cover Boosh.
Yamabond sealant works very good. I got this at my local Honda dealer.

 

The bottom of the gasket got a little oily...will that stick to it?

 

you got nothing to lose by trying JB weld but i never found the stuff much useful for anything but fixing abs fairings and only sparingly

 

something i learned is that if you can't tighten all bolts by hand almost fully, something isn't lined up right or clearing something right, so remove the assembly and study the fitment.

Don't depend on a wrench or tightening a socket to finish aligning parts.

 

So long as you work it in there and take your time it should work just fine. Dad did the same thing on my 4-wheeler over 20 yrs ago. It held up for the 15+ years I rode it, 5 years for the guy that bought it from us, and then was still going strong when he sold it.

 

its the dowels, or the pin that holds the starter gear to starter clutch combo...can possibly do this if it is not in deep enough...almost happened to me last night...know what i mean??

 

In hindsight, it was likely the pin that holds the starter gear to starter clutch combo. I thought I'd be smart and install the cover before the JBWeld fully cured. It's simply amazing what a couple love taps did. I ran the machine yesterday and let it get up to 200F. I then rode it home from where I was working on it...only about a km. I checked her this am, no leak!!

Thanks fellas!

What can I phuque up now?!??

 

Thats what I was trying to tell you...If it doesn't go in right into the center of the gear and block its impossible to get the cover on.

 

In the future.....
All bolts on any assembly should be HAND tightened until the part is in position and then tightened with a wrench or socket.

Yes it was a beginner mistake.

The case may need to be TIG welded, but since we cannot see it it is hard to tell.