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Cracked the case

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Just dumped my DRZ last night. Thought no damage but now seed the shifter dented and put a slight crack in the case. Now it is leaking ever so slightly.  I was just about to install the case covers.  Crud. Now do I need to replace the entire case on the shifter side?  It is a small dent right where the shifter hit it.  Maybe some jb weld could do the trick?  If that does not work where should I look for the new case?

 

Damn those are brittle. 

 

Greg

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Jb weld might work depending on the size of the crack. When I first got my drz it already had case savers on it, but I pulled off the stator cover and saw there was a HUGE hole in the case lol. The guy just threw the case savers over top of the hole. Still holding up just fine to this day.

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It is a pretty small crack, any a tiny hole the size of a pencil tip,  The small dent/crack is smaller than a dime, right where the shifter hit it. I may try the JB weld.  If that does not work then I will have to get a new case. Either way the case saver will go ontop afterwards.  I just dumped it right in the driveway after a good ride.  Stupid mistake but seemed harmless, until I saw the leak in the morning...

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Cure time makes a big difference with Jb weld. Give it at least 24hrs before you put it back on the bike. Doubt a new stator cover is necessary, as long as it holds oil who cares.

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I guess that little chain case protector has a use, what happen to yours?

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Damn those are brittle. 

Those are Magnesium, thin, lightweight and yes, if you hit them with a sharp edged shifter lever it will crack the case cover. 

 

Try cleaning and slathering in JB weld, then cover with a case saver, Many have good luck doing so. 

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It is a pretty small crack, any a tiny hole the size of a pencil tip, The small dent/crack is smaller than a dime, right where the shifter hit it. I may try the JB weld. If that does not work then I will have to get a new case. Either way the case saver will go ontop afterwards. I just dumped it right in the driveway after a good ride. Stupid mistake but seemed harmless, until I saw the leak in the morning...

dont feel bad about dumping it in the driveway and suffering this damage, mine fell over in the garage and the shifter put a quarter size hole in the cover. No jb weld for that one, the local parts guy felt so bad for my bad luck that he sold me the new cover at cost!

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Those are Magnesium, thin, lightweight and yes, if you hit them with a sharp edged shifter lever it will crack the case cover. 

 

Try cleaning and slathering in JB weld, then cover with a case saver, Many have good luck doing so. 

 

+1...The JB should patch ok. when the case saver goes on , it would probably cover the damage area as well..

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Is it worth the OP looking INSIDE the cover, to make sure nothing's flaked off the inside and is now prepared to float around in the oil, causing mayhem?

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Is it worth the OP looking INSIDE the cover, to make sure nothing's flaked off the inside and is now prepared to float around in the oil, causing mayhem?

 

Yes, I would have a look....

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FWIW these can also be welded if need be by a specialist shop.

 

There was a crack in my clutch cover when I bought the bike. Something similar to JB weld was used by the PO and then again by myself. It didn't hold - it cracked under vibration. (I think the compound was actually something less strong/flexible than "real" JB Weld.) But I was told that these could be welded - and found a local aluminium repair specialist that will do it. 

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Is it worth the OP looking INSIDE the cover, to make sure nothing's flaked off the inside and is now prepared to float around in the oil, causing mayhem?

 

 

it's always a good idea, yes. the stator cover usually breaks in a large triangular shaped piece, if it lets loose of a piece. but, with all those expensive little tiny pieces of engine that don't like injesting other pieces of shiny metal, yes, it's a very good idea.

 

after punching my case (with and without the TT guards, they're pointless) several times, i'd say it's best to do what erik mentioned about, grind or file off the sharp edge of the shifter, remove the case and blast it with brake cleaner, THEN jbweld it. it will hold just fine IF ITS CLEAN AND DRY when you apply the jbweld to both the inside AND outside. just the outside without cleaning means you're trying to bond to oil covered magnesium = fail. maybe not today, but soon. ;-)

 

jbweld -is- the fix, unless you want to spend a few hundred dollars each time you punch the case. ;-)  TT case savers barely change the likelyhood of punching a case. after fixing it the 8th or 9th time, i cut up a piece of carbon fiber and glued it on with SHOEGOO and it's been protecting the case very nicely for over a yaer now... without changing the heat shedding characteristics of the case. 

Edited by ohgood
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Thanks for the posts. I will remove and clean and inspect and them try the jb weld inside and out .. it is a small but effective crack

1399391424560.jpg

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Is there anything i need to be aware of when removing the cover? It seems straight forward but my manual does not have a clear instruction. Wants to remove engine first..

Seems like i can just remove bolts after draining the oil

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Use an Impact driver and #3 bit to remove the TQ limiter cover.

Dont forget the case cover screw behind the TQ limiter :lol:

Many times the starter motor in the cover makes removal of the cover difficult.. Best practice it to remove the starter motor FIRST if this is the first time you have R&R'ed the cover .  

Don't loose, loose track of the dowel pins in the cover/ motor.

 Don't loose, loose track of the starter TQ limiter bushings.

Don't loose track of the starter idler gear shims.

DO look at the FAQ and see what the recommended placement of those starter idler gear shims are. 

The cover has several components that make it feel "stuck"  It has to come off evenly,,, get it cocked and the dowel pints will jamb and make the cover feel stuck. As will the starter stuck in the cover (see suggestion above) 

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Same thing happened to me not to long ago lol. JB weld has been holding up nicely.

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Will I need a magneto gasket and/or other gaskets / o rings?  I believe the "magneto gasket" as refered to by the OEM parts diagram is the case cover gasket for the starter side, if I am looking at it correctly.  I believe there is also an oring on the starter motor assembly, that likely does not need replacement.  I just want to be prepared when I crack open the case to inspect and repair the hole.

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