[handikapsk8r]

I'm new to posting on this forum but I've been creeping on it for months ever since I had to do some real work on my t dubb.



Recently I kicked over my bike and the case broke into pieces around the kick lever. Has anyone else had this happen or am I the first. The bikes an 89 with 4000 miles all dirt due to the previous owner hacking the harness up.



Is the broke case common or just the last part to replace in my basically complete bike overhaul. ( just did complete top end, valves rings piston, new clutches, new brakes, and new sprockets,) can I expect this to happen again?



Please help me I think I got a money pit.

 

[RisingSun]

You just got some bad luck. Its cast aluminum it can break on any bike

 

[handikapsk8r]

Ain't that the truth I'm just wondering if there's an underlying issue that needs to be addressed before slapping a new one on and breaking it too

 

[qwerty]

Unless there is some workmanship error in installing the case or the parts underneath, I concur with the bad luck theory.

 

[operose]

This is one of the areas on a tw that I would fix, if the idea was to build a last forever machine.



The kick start shaft is poorly supported inside the case, and then not actually supported by the case at all, where it passes through. There is just a rubber seal between kickstart shaft and engine case.



Unfortunately I don't think this could be replaced with a bushing&seal or bearing&seal, as this would probably transfer the force into the engine case, resulting in the same problem junk rider has.



Just some food for thought.

 

[handikapsk8r]

I'm wondering if the constant drops it takes on the ga trails may have weakened it and it finally gave out.



I have broken two return springs on it so maybe a few to many spills on the lever itself is the culprit



Thoughts?

 

[Dave Nafziger]

My '89 cracked open from kick starting it; it split about 5", but not into pieces. I have never been able to account for it. -DN

 

[handikapsk8r]

Maybe I should have been slightly more clear it didn't break into pieces as much as it broke a section about 2 inches in diameter around the kick start lever

 

[Dave Nafziger]

My break was counter clockwise from below the shaft hole, to a point about an inch over the 'Y' of the Yamaha letters.

I don't bottom out as hard any more, and try to kick in an arc. Are you welding or replacing yours? -GB

 

[handikapsk8r]

Replacing. Found them new for 112 at cyclepartsnation.com I found one on eBay right now so please don't sniper me. I tried to flux less weld the case back together but as soon as a kicked it over it broke right back off so a replacement is the only way to go

 

[handikapsk8r]

Thanks to anyone who read this thread and didn't outbid me in eBay I thank you all

 

[bonkas2]

Any luck getting it fixed?