agricon Posted February 14, 2013 Report Share Posted February 14, 2013 Hi, I am looking for some help or advice on where I may be able to get a replacement clutch casing for my TLR200. Unfortunately at a recent trial I damaged it and it now has a leak. Thanks in advance. Andy from NZ Quote Link to comment Share on other sites More sharing options...
bashplate Posted February 14, 2013 Report Share Posted February 14, 2013 the covers will ally weld ok....you just need to find an engineering shop that can do it. Quote Link to comment Share on other sites More sharing options...
agricon Posted February 14, 2013 Author Report Share Posted February 14, 2013 the covers will ally weld ok....you just need to find an engineering shop that can do it. Hi Bashplate, Unfortunately its not as straight forward as that. What happened is that while riding over a large rock the sump guard hit it very hard. So much so that the force transferred through the guard and onto bottom foremost screw hole of the casing. It has deformed the hole and forced the casing to bend albeit very slightly but enough to now leak oil. So any welding would need to be done on the flat surface and then re-machined to give a flat face again. Quote Link to comment Share on other sites More sharing options...
axulsuv Posted February 15, 2013 Report Share Posted February 15, 2013 On my TL125 , when I was 12 or so , (bike was new !) I cased it hard enough to crack the left case and shear a couple of case bolts ... My Dad had a machinist/welder buddy and needless to say a week later I had my bike back ... It can be repaired , you just need to find someone with the skill to do it ... And he also built a skidplate from a Ossa pioneer bottom and welded wings on it for the TL side cases ... Worked a treat ! Glenn Quote Link to comment Share on other sites More sharing options...
shyted Posted February 15, 2013 Report Share Posted February 15, 2013 Agricon , do you have a picture you can post ? As if you can't or don't want to get it repaired ,maybe some of the sites brother hood can help you out ,or maybe it's the same part as one of the XL/XR range whereby you can make do . Just a suggestion . Regards Ted Quote Link to comment Share on other sites More sharing options...
agricon Posted February 17, 2013 Author Report Share Posted February 17, 2013 Agricon , do you have a picture you can post ? As if you can't or don't want to get it repaired ,maybe some of the sites brother hood can help you out ,or maybe it's the same part as one of the XL/XR range whereby you can make do . Just a suggestion . Regards Ted Hi Ted / GlenThanks for your replies. I guess when I posted I was just looking for a "quick fix" and maybe find an other casing for the TLR. However I now realise that's probably not going to happen. Since posting I think I have managed to source a casing from an XR200 and I will see if this fits. I think the original casing could be repaired. I just have to find someone who can do this here in NZ. Thanks again Andy Thanks Andy Quote Link to comment Share on other sites More sharing options...
tltel Posted February 17, 2013 Report Share Posted February 17, 2013 Hi Andy By coincidence I have just had this problem with an xr125 that I bought for my son, I was told when I bought it that it had a slight oil leak from the clutch side and that the cover had been replaced, I did buy the bike as a non runner. Got it running and found the slight leak to be a gusher. bought new gasket and fitted it with a bit of gasket dressing/ sealer, still gushing. Took it apart again and found a hairline crack in the crank case where the bottom front screw fits.Today I have sealed it up with the silicone gasket sealer (I hate this stuff and dont like to use any thing on new gaskets ) Fitted another new gasket and its fine, ran it through a few heat cycles and no sign of oil leaks. I will be looking for a replacement crankcase half once I have got the bike road legal. The reason for that waffle is, Make sure you clean and check the crankcase before you put on the new cover, I wasted half a day today and a gasket and oil and didnt get to take the gas gas out. TLTEL Quote Link to comment Share on other sites More sharing options...
agricon Posted February 18, 2013 Author Report Share Posted February 18, 2013 Hi Andy By coincidence I have just had this problem with an xr125 that I bought for my son, I was told when I bought it that it had a slight oil leak from the clutch side and that the cover had been replaced, I did buy the bike as a non runner. Got it running and found the slight leak to be a gusher. bought new gasket and fitted it with a bit of gasket dressing/ sealer, still gushing. Took it apart again and found a hairline crack in the crank case where the bottom front screw fits.Today I have sealed it up with the silicone gasket sealer (I hate this stuff and dont like to use any thing on new gaskets ) Fitted another new gasket and its fine, ran it through a few heat cycles and no sign of oil leaks. I will be looking for a replacement crankcase half once I have got the bike road legal. The reason for that waffle is, Make sure you clean and check the crankcase before you put on the new cover, I wasted half a day today and a gasket and oil and didnt get to take the gas gas out. TLTEL Hi TLTELThats useful information. I will check to ensure there is not a hairline crack in the crank case. Many thanks Andy Quote Link to comment Share on other sites More sharing options...
gasgasstu Posted May 20, 2013 Report Share Posted May 20, 2013 Andy, I just bought a TLR and found a crack in exactly the same place. Someone had put chemical metal over it. But on taking the cover off to put new clutch plates and heavy duty springs I could not get the cover off. So I cleaned the filler off and low and behold was a bolt which I finally got out as it was bent due to the impact. So on inspection found the crack. so I done my clutch plates and springs and for now put new chemical metal until I can get it welded. I have a very slight weep of oil but not enough to stop me using the bike. Done my first trial on it on the weekend,12 points dropped and no oil problem. Quote Link to comment Share on other sites More sharing options...
agricon Posted May 22, 2013 Author Report Share Posted May 22, 2013 Sounds like a good result all round:-) Quote Link to comment Share on other sites More sharing options...
gasgasstu Posted May 22, 2013 Report Share Posted May 22, 2013 Yep good result I actually won so well happy, can't wait for the next one Quote Link to comment Share on other sites More sharing options...
hondanut Posted May 23, 2013 Report Share Posted May 23, 2013 the casing from an xl or xr are not the same as the tlr one is more like the shape of the inside components, but it may fit as the moulding holes ect are the same, i have all 3 of them and there are differences but i think the tlr one is just a little more shaped, the only difference between an xl and xr one is tha xr one is blanked off where the rev counter goes, but it is easy to seal up the hole on an xl one. i had my xr 200 clutch casing welded as it was leaking where someone had tried to tighten it down without the clutch being right and just snapped off the botteom hole. but i am in the uk not far from a specialist welder! Quote Link to comment Share on other sites More sharing options...
tlrmark Posted May 23, 2013 Report Share Posted May 23, 2013 The XL185,XL200 and XR200 clutch casing are a bolt on, to a TLR200 crankcase. I have done this and they are completely interchangeable, oil galleries in clutch cover line up exactly etc. The only difference is the cosmetic external shape of the cover looks different. I have several XR200R engines and use the TLR covers on those as well, so swapping either way is not a problem. The TLR cover sells for big bucks on ebay. The XL/XR200 clutch covers are a fraction of the price and much more common, used, on ebay. Quote Link to comment Share on other sites More sharing options...
gasgasstu Posted May 23, 2013 Report Share Posted May 23, 2013 Hey thanks Mark, that's an option I can use if the casing gets worse. I expect the internals are pretty similar except for gear ratio and bore Quote Link to comment Share on other sites More sharing options...
bashplate Posted May 24, 2013 Report Share Posted May 24, 2013 thanks Mark, that's usefull knowledge Quote Link to comment Share on other sites More sharing options...
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