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Pitting/holes in clutch caising Pitting/holes in clutch caising
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 1 Jan 2020
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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.
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  #2  
Old 1 Jan 2020
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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?
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  #3  
Old 2 Jan 2020
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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.



Mezo.
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  #4  
Old 2 Jan 2020
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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.
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  #5  
Old 3 Jan 2020
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Quote:
Originally Posted by Speedy Gonzales View Post
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.
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Old 4 Jan 2020
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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
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Old 5 Jan 2020
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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.....
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Old 5 Jan 2020
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Originally Posted by turboguzzi View Post
can you put a bigger picture so we understand better?

Click the picture and you'll get a much bigger one, nicely detailed.
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Old 5 Jan 2020
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Quote:
Originally Posted by Mezo View Post
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.



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

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Old 6 Jan 2020
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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.
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Old 6 Jan 2020
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Quote:
Originally Posted by Grant Johnson View Post
Click the picture and you'll get a much bigger one, nicely detailed.

i did of course but i meant a picture of the complete cover to assess overall condition
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  #12  
Old 6 Jan 2020
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Quote:
Originally Posted by Speedy Gonzales View Post
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.
Just brush and clean it before good luck

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  #13  
Old 9 Jan 2020
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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.
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  #14  
Old 10 Jan 2020
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Quote:
Originally Posted by Speedy Gonzales View Post
what is the best way to take out he plugs for kick and decompsystem ?
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.
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  #15  
Old 28 Feb 2020
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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.
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