Cracked Case

[atvrider23054]

Ok, I went riding last night for like 2 hours. I lubed my chain, but didnt realize that it was a little loose. To make a long story short I'll just cut to the point. I went off a little jump we have at our track and while in the air hear a loud crack and thump. I land and it was like I was in neutral. I look to see and the chain lapped around the front sproket and craked the case. Now I'm gonna see if I can JB Weld it. Anyone have any other suggestions? Anything else can be wrong?

[atvrider23054]

chain

[atvrider23054]

crack. I still have the peice that cracked off. Thats why I think i can JB weld just the cracks around the peice when I fit it in.

[05Z400rdr]

That really sucks. Good luck with the JB weld...let us know how it works out for you.

Also, I strongly suggest a case saver!...thats what they do, well supposed to do - save the case. One time my chain took a chit on me like that once, but since I had a case saver, the only thing was that it broke that in half. I put another one on and it was all good.

Good luck dude


Landon

[atvrider23054]

well, hahah.. I had a case saver, but I guess it was a cheap kind. It snapped right in hafl and the chain still hit the case.

But thanks for the replies.

Im gonna JB Weld it tomorrow, then have my buddy Matt reinforce it with some sort of weld.

I'll tell you guys how it goes and post some pics of the procedures incase it happens to someone else.

[07250ex]

wow the chain whips of those sprockets with alot of force huh

[YFZ450Ridr]

same thing happened to mine except it wasnt quite as bad. i used a 2 part stuff you mix called Devcon. it worked extremly well and held up great. you mix a 4:1 ratio of this stuff they give you and just smear it on and let it dry. i never had any leaks what so ever once i did mine. im not sure how it will work for you seeing as you have a major chunk missing, mine was more of a large crack. give it a shot though!

[atvrider23054]

Ok, Ill give that a shot... I forgot to say that I do have the chink thats missing so all I have to do is fill in the cracks around it with JD or that Devcon (sp?) stuff.

Which do you guys think is better Jb or Devcon?


The part I'm most frustrated about fixing is getting the chain unstuck.:(

[the fat kid]

yeah dude that sucks btu i got the stock case saver on and my chain came off like 4 times today and wound up on the front just like yours did, and no cracks, well i dont think so anyways.

[atvrider23054]

Originally posted by the fat kid
yeah dude that sucks btu i got the stock case saver on and my chain came off like 4 times today and wound up on the front just like yours did, and no cracks, well i dont think so anyways.

Its annoying taking the chain off the sprokets when its like that

[atvrider23054]

O yea and when I get this thing fixed, I'll take a picture of our little track and stuff

[snacob14]

this is about the fifth one i've personally seen. Are you running a 13 tooth or stock. I'm just wandering if this is the common denomiator. my bro in law cracked his second gear, it totally sucked

[atvrider23054]

So today it took me a good hour and a hlaf to get the chain unraveled. I get a pic tomorrow. and now i just have to clean up the area and get JB weld on it.

As for the sproket question... Idk ill have to see tomorrow, but im pretty sure its the stock size.

[the fat kid]

dude look most of the time when its like that determine what direction it needs to go and put the bike in a gear that will unravel it for you, like mine i usually have to put it in reverse and then just barley let out the clutch and it will free itself...

[atvrider23054]

Originally posted by the fat kid
dude look most of the time when its like that determine what direction it needs to go and put the bike in a gear that will unravel it for you, like mine i usually have to put it in reverse and then just barley let out the clutch and it will free itself...

Too late for that now, but I will try that next time.

[400exrider707]

I wouldn't JB weld that... I would suggest a new case for that one, that is a big chunk missing.

[atvrider23054]

Originally posted by 400exrider707
I wouldn't JB weld that... I would suggest a new case for that one, that is a big chunk missing.

Yea, but I have the chunk that came out. It's still in one piece.

[atvrider23054]

does anyone know if I can just slip the cover off (the one right next to the sproket) with just taking the bolts out? I think its the stator cover... kinda new to this z400 thing

[nator187]

You need to take all the 8mm bolts off you can see along the outside edge of the cover. Then take the 3 8mm off the small cover and remove the small cover and gear assembly(Watch out for the washers on bot ends of the gear and the o-ring on small cover is like $13 so don't cut it). inside there you will find another 8mm bolt that needs to be removed. Now the side cover will come off sith little force. Mind you there is a big magnet in there so it might take some pressure to remove the case but not a while lot.


Woody

[atvrider23054]

Ok, from what I can see the Jb weld seems to be holding up well. Now I figured out why my chain got loose all of the sudden, the chain adjuster bolt in the back snapped in half. No i have half wiggling around and the other half threaded in. I'll have to see if I can take it out tomorrow. ( I'll try to get pics of everything tomorrow )

[atvrider23054]

Can I just weld the half that snapped off to the swingarm and still be able to use the adjuster or what? Not really sure how it works. Also whats the part callled that the chain adjuster bolts screw into?

[Quad82DP]

PM Bellsbub. He has a fix by using threaded rod.

[05Z400rdr]

Originally posted by atvrider23054
Also whats the part callled that the chain adjuster bolts screw into?

That's the carrier

[atvrider23054]

Ok, ill see if I can fix it. If not I'm just gonna order a new carrier if i can or get one on atvriders for sale section

[Quad82DP]

Your case can be repaired. Looks the same as one of my cases did. The clutch shaft has no pressure there. Looks like the top and bottom bearing cups are in tac. The rest of the column is just a shaft cover. Pull the clutch shaft, rubber seal, bearing and shaft out. By also pulling the right side cover and flywheel off, you have enough room to weld a cap over the hole. There are no seals that will be harmed by the heat of the weld. If you end up splitting the cases and pulling the guts out, you can send it to me and I can get it done for you. Sure beets $300 to $500 for replacement cases.

[atvrider23054]

Originally posted by Quad82DP
Your case can be repaired. Looks the same as one of my cases did. The clutch shaft has no pressure there. Looks like the top and bottom bearing cups are in tac. The rest of the column is just a shaft cover. Pull the clutch shaft, rubber seal, bearing and shaft out. By also pulling the right side cover and flywheel off, you have enough room to weld a cap over the hole. There are no seals that will be harmed by the heat of the weld. If you end up splitting the cases and pulling the guts out, you can send it to me and I can get it done for you. Sure beets $300 to $500 for replacement cases.

Thanks very much I really appreciate it, but I already fixed the case. If it doesn't hold up I'll let you know

[atvrider23054]

Now I need to look for a stock carrier. Is there anywhere I can buy one new? IF not I'll just have to get one used.

[05Z400rdr]

There's a number of places that you can get OEM stuff..

Your dealer, Ronnies (http://www.ronnies.com), RivaRacing (http://www.rivaracing.com)

if you get a brand new OEM one, don't expect it to be too cheap either...


Landon

[atvrider23054]

Ok, thanks. Can anyone help me and explain to me how to get the carrier out? I really do not know. I need a step by step kinda thing.