cracked case!!

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Pelican

Guest
I need help...have been trying to wait patiently for case covers to arrive from the states for the past few days, and taking the riding kinda easy as I have read in this forum and many other places that the crankcase and generator rotor covers on the DRZ 400's are quite fragile...but sure enough, I've gone and made a small puncture with the shifter. After closer inspection, it looks like it has been patched before...does anyone know how I can repair the case well enough to keep riding? There is a slow leak now...like, maybe 48 hours and there will be a drop formed on the underside of the case...I just need to stop the leak, then fire those covers on when they get here...I read somewhere just the other week about a patch job...can't remember where. Anyone experienced with this? Does it need to be welded?

Pelican
 
Island Hopper

Island Hopper

New member
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Epoxy formulas like JB Weld or quick steel puddy work great for repairing case fractures. The secret is to prep the surface real good, make sure it's clean and give it a good rough texture sanding or rasping before applying epoxy.
 
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Pelican

Guest
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Cool...I can find this at any automotive place?
 
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Shawndude

Guest
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I broke the case on my very first ride on the green DRZ.

Another vote for JB weld here. This stuff is great. Canadian tire has both JB weld quick and regular. The regular is stronger, but I used the quick one and works perfectly on the covers.
 
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dirtdoug

New member
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Maybe I'm missing the point here but if it's leaking very little and you've ordered new cases why not just keep topping it up? Oil's cheap.

Besides you can pretend you have an old British bike :tup:
 
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leadsled

Member
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Doug,



He ordered new covers not cases. On a drz they come with crappy magnesium cases that can crack easily. There are Aluminum covers that you epoxy onto the cases for added protection.Best to repair the case then add the covers. I have a few good dings in my covers but no cracks in the cases which i am sure would have wrecked the cases without the covers.
 
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Pelican

Guest
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Excellent choice of words lead...crappy magnesium cases...it really blows my mind the cases are so fragile. Anyways, should have updated a long time ago, but bought some JB, roughed up the surface (not hard, see comment ref crappy cases!), didn't worry too much about how pretty it looked, because as soon as it cured I put on my case guards from Thumper Talk...not bad, wish I had of know of the problem earlier. Oh well, learning lots the more I ride, and from this forum as well. Still haven't made it out for a ride with anyone from the forum, seems like most of the island riding happens down south...oh well, one of these days. Thinking of installing a kickstart kit on my DRZ, I have been asking about them since I bought my bike second hand, and no one has ever said it could be done, from Suzuki dealers to the internet...but I stumbled across this the other day, and I really think it would be worth it. Should ask around the club and see if anyone has done it I guess...

http://mr-cob.smugmug.com/gallery/136763/1
 
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