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i have now cracked my magnesium clutch cover twice. i don't even remember how it happened this last time. no crash or memerable impacts. this is caused by the brake lever being pushed into the cover. i have heard of this problem with other x riders. any ideas on how to prevent this from happening?

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i have now cracked my magnesium clutch cover twice. i don't even remember how it happened this last time. no crash or memerable impacts. this is caused by the brake lever being pushed into the cover. i have heard of this problem with other x riders. any ideas on how to prevent this from happening?

Read the stickys at the top of the forum or do a search for more info.

What many do, some or all:

- grind off teeth on pedal closest to cover

- wrap edge with a scrap piece of tire sidewall using safety wire

- glue on a section of stainless steel, or thick abs sheet to clutch cover

- get a Hinson clutch cover

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Even with the SFB ( my fav) you need to lower the brake pedal as far as you can. I think the rubber on the tip idea is great but still have yet to apply it to my bike.

I have caved in my SFB even with the lowerd brake lever, luckily all I had to do to fix it was clearance it on the inside when I got home, the basket was rubbing, not enough to cause a problem but it was noisy on the way home.

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Read the stickys at the top of the forum or do a search for more info.

What many do, some or all:

- grind off teeth on pedal closest to cover

- wrap edge with a scrap piece of tire sidewall using safety wire

- glue on a section of stainless steel, or thick abs sheet to clutch cover

- get a Hinson clutch cover

I’ve done the first three. It still shatters when crashing in rocks.

IMG_3823.jpg

In the end you are better off getting a thicker aluminum one.

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Whatever you do for an aftermarket, do yourself a favor and dont waste your $80 on a Boyesen cover. They are crappy cast aluminum and the stud holes crack as soon as the thing gets put on. Id show you a picture but I would be wasting precious MB on my camera on that crap cover.

Make sure the one you buy is billet aluminum.

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Not happy with my Pro Circuit Billet clutch cover. It spits out O-rings no matter how carefully you mount the cover. The groove for the O-ring does not match the sealing surface on the crankcase cover at the bumpouts at 2 and 7 o'clock. I have put the O-rings on dry, with grease, with glue all to no avail. I position the cover to get the best seal but after about 100 miles of riding I see a portion of the O-ring sticking out, touch it and it falls off because it has been cut. I have installed and removed the cover a few times, inspecting the o-ring each time and I am not damaging the o-ring on install, run the bike for a few hours and the o-ring fails.

Anyone else having this problem?

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Not happy with my Pro Circuit Billet clutch cover. It spits out O-rings no matter how carefully you mount the cover. The groove for the O-ring does not match the sealing surface on the crankcase cover at the bumpouts at 2 and 7 o'clock. I have put the O-rings on dry, with grease, with glue all to no avail. I position the cover to get the best seal but after about 100 miles of riding I see a portion of the O-ring sticking out, touch it and it falls off because it has been cut. I have installed and removed the cover a few times, inspecting the o-ring each time and I am not damaging the o-ring on install, run the bike for a few hours and the o-ring fails.

Anyone else having this problem?

Not a problem on my PC in 2 years. It's been beaten half to death but is still holding up pretty nicely. Is it possible you have the wrong cover?

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Not happy with my Pro Circuit Billet clutch cover. It spits out O-rings no matter how carefully you mount the cover. The groove for the O-ring does not match the sealing surface on the crankcase cover at the bumpouts at 2 and 7 o'clock. I have put the O-rings on dry, with grease, with glue all to no avail. I position the cover to get the best seal but after about 100 miles of riding I see a portion of the O-ring sticking out, touch it and it falls off because it has been cut. I have installed and removed the cover a few times, inspecting the o-ring each time and I am not damaging the o-ring on install, run the bike for a few hours and the o-ring fails.

Anyone else having this problem?

No problems on our two 450X's. We have had Hinson, Boyesen and Rekluse covers. What I would do, get new OEM O-ring and put it in freezer with the clutch cover. O-ring stays in the cover pretty good with this method for installation.

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Not happy with my Pro Circuit Billet clutch cover. It spits out O-rings no matter how carefully you mount the cover. The groove for the O-ring does not match the sealing surface on the crankcase cover at the bumpouts at 2 and 7 o'clock. I have put the O-rings on dry, with grease, with glue all to no avail. I position the cover to get the best seal but after about 100 miles of riding I see a portion of the O-ring sticking out, touch it and it falls off because it has been cut. I have installed and removed the cover a few times, inspecting the o-ring each time and I am not damaging the o-ring on install, run the bike for a few hours and the o-ring fails.

Anyone else having this problem?

i have been running the pc for around 2 years, the o ring was a pain to get in the groove as it was with the sfb as well, but no problems with the o ring coming out once its in good. maybe you should contact pc about this problem and see if they can help.

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