Pitting/holes in clutch caising
 

Hi !
I have a XT 600 Tenere 87 mod and over a time the bike have been leaking oil from the bottom of casing. I tought it was bad windings so I was not able to tighten the bolt. Now I got time to try fix it and then I see that there is a lot of pittings inside the cover and a hole whre the oil came out. A new cover is not possible to get as I can`t find anything on internet.
Is there a way to fix this, welding, soldering, liquid metal or other things that will make it useble again.

allegedly looks like fatigue but not easy to believe since it shouldn't be under specific stress IMO..
if it's repairable with TIG (have no suggestions about other methods) I'd try to find someone really best in this field since besides the hard to reach areas it's about the further durability as well..
maybe someone knows here the type of this alloy and it might also help somehow..
what about gasket silicone, was there any difference in leakage with it?

Looks like the clutch side? Its the same cover as the 3AJ (same part number) 1VJ-15411-00-00 ONE HERE IN ITALY.

Or just JB WELD it.

https://images-na.ssl-images-amazon...._AC_SY400_.jpg

Mezo.

Thanks for tips, I order the cover but will try to JB weld the the one I have to see if it will hold because the metal is soaked in oil and it will be a challenge to get it clean enough.

Use brake cleaner (spray can) its similar to trichloroethane but they banned its use, i think they use tetrachloroethylene now but use carefully in well ventilated room, use gloves & don't breathe it in (carcinogenic) but it will clean your parts spotless.

Mezo.

Hi Speedy

I recently saw an advert for a new (to me) method of welding aluminum by applying heat to the metal using a blowtorch and then applying to the heated metal an aluminum rod that melts and flows in to the gap / hole to be fixed. The process looks very similar to brazing so it might be just what you need to fill in all the pits in your casing. I have not tried it so I do not know if it works or not. Here is a link to to website for your information.
https://hazellab.com/products/alumif...1229b04e&_ss=r

can you put a bigger picture so we understand better?


for parts, try italian ebay (coperchio frizione) and german ebay (kupplung deckel) ebay, these bike sold lots in these markets, no shortage of parts.....

Click the picture and you'll get a much bigger one, nicely detailed.

Another option aluminum braze on
https://youtu.be/U10ncaktR74

Sent from my Z981 using Tapatalk

Thanks for tip about brazing/soldering, I will give it a try when I get he cover I order on Ebay. I want to see the condition of that before i do somehing, I will try soldering the cover he cover in worst condition.

i did of course but i meant a picture of the complete cover to assess overall condition :)

Just brush and clean it before good luck

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Got the used cover today and it looks in good condition with no damages.
I will try to solder the old one just to see if it can be done.
The new cover is fo a newer model without kick so he holes is plugged, what is the best way to take out he plugs for kick and decompsystem ?
I need to get some new seals and the reurn valve for oil before I put it back together, will go away for work the next 4 weeks so I will order the parts so everything is ready when I get home.

Thanks again for the tips on this problem.

The plug just knocks out, i have a 3AJ that has had a kicker conversion done, id imagine the decomp is the same i forget?

Mezo.

Finaly got time to continue and this bike is giving me some hard time again.
The new cover is good but there is one issue, there is a hole where the decomp cable goes in but it is 6mm and the cable is 7 mm, can I use a drillbit to make the hole bigger so the cable goes in ? See picture.

Don't see why not, possibly just been crushed closed a tad, don't try to pry it open or it will snap so yes just drill it out.

Mez.

That was I thinking to so I took my dremel and open up so no it fits. Cover is back on, oil filled up but battery was dead so i will get a new one before I start it up.

It still gives me a struggle, after start it was leaking oil from a hole behind the oilfilter, after looking at drawings it seems that there should be a oilpipe from that location and over to the other side of engine.
I can not se any place fore that pipe on my engine as is a 1VJ and the cover is from a newer model.
Can I just put a screw in that outlet and blind it of without making any damage to my engine ?

yes, it's the external oil feed for the gearbox of the newer models. you can plug it, but make sure to use the right thread. the banjo fitting that goes there (most likely an 8 X 1 thread) will have finer thread than a typical M8 x 1.25 bolt. your plug should thread in nicely, dont try to force a normal M8 x 1.25 bolt there or you'll ruin your new cover...

Thanks for the information but i did just that, put in a M8 bolt and no leakage so far. Hopefully it will last for a while, if it start leaking I will drill it and put in Helicoil.

Hi again !
Now the bike is running good and there is no oil leak :thumbup1:
But I got a slipping clutch so that will be the next task.
Thanks again for all help and tips :clap: