garydwall Posted yesterday at 05:24 PM Report Share Posted yesterday at 05:24 PM Hello, I replaced the cover 3 months ago and it is cracked again, I have read posts but am still confused why the cover cracks...... Only thing is engine can backfire sometimes when kick starting, could that do the damage?? Bart gear, bearings etc were all replaced also...., small washer fitted on kickstart shaft.... Thank you 1 Quote Link to comment Share on other sites More sharing options...
feetupsbetter Posted 18 hours ago Report Share Posted 18 hours ago It is a fairly common occurrence sadly. If this has only been fitted 3 months, how long did previous one last ? There is obviously some way to assemble everything together which then applies an unexpected loading to that particular bore/shaft housing which causes these failures. I notice a wear mark on the case where it steps out around the clutch basket itself, which suggests something has been regularly rubbing against it, that would be worth checking for lever boss clearance. I’ve also wondered if the position of the lever when mounted can have some detrimental impact. When the lever is rotated down & strikes the footrest as a dead stop, the internal rotating mechanism (Bart gear) will be in a different position depending on which spline position is used. If the lever & shaft rotates too far (maybe just one spline out), could the Bart gear be striking some part of the inside of the case ? That would add a leverage force trying to move the shaft relative to the case which combined with the shock dead stop would add a significant stress to the case at every ‘kick’ action. Just a thought, but quite difficult to check the operation although there would be a tell tale mark somewhere. Good luck with the next one ! I ran a couple of these bikes (maybe 03 & 05 models ) over about five years and never had the problem with the cracked case just the Bart gear & idler having chipped teeth. Quote Link to comment Share on other sites More sharing options...
lineaway Posted 17 hours ago Report Share Posted 17 hours ago This was actually more of a problem on the 2004-2004 300cc models. Could be the position of the lever to over rotate. Due to the bart gear. Also getting the correct timing of the parts during assembly was critical. Jim Snell had great diagrams and video's on this. Quote Link to comment Share on other sites More sharing options...
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