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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Clutch cover conundrum.
Post Info TOPIC: Clutch cover conundrum.
colin4935


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Clutch cover conundrum.
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I fitted a new clutch to my TTR and replaced the Gunk that a previous owner has used with a proper Gasket. At the end of a long Distance Trial I discovered that the bike had dumped most of its oil. During remedial surgery I noticed that on both the clutch casing and the engine casing there is evidence of a very small hole having been drilled on the join at the rear of the casings, an obvious place for the oil to escape. Is this hole supposed to be there?? Grateful if anyone has any suggestions.

Colin4935

PO Gash1.jpgIMG_0880.JPG



-- Edited by colin4935 on Monday 24th of October 2016 12:42:37 PM

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TTRfan


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threadbetterwithpics.gif

 

Hi Colin

Sorry to hear of the problem.

I am pretty sure that a PO did that. No reason to add a breather hole at that point but a photo of the offending hole would let us say for sure wink

Brian



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colin4935


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Thanks Brian

I am tempted to just clean it up and fill it, will post photo tomorrow. Sorry to be a luddite, PO?

Colin 4935

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TTRfan


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colin4935 wrote:

Sorry to be a luddite, PO?

Previous Owner wink 



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colin4935


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Probabley why they used a gasket solution. Thanks for your help but why anyone would want to drill a hole between the casings is way beyond my ken, I shall post a photo of the broken exhaust manifold stud workaround, that will make you smile.  



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ttr steve


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Looking forward to seeing said photos!



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colin4935


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Added photo's to original post. You can see what looks like a hole that has been fashioned both sides of the casings. It is not a drilled hole more like a bash with a screwdriver/chisel.

Filled with epoxy now and fitted back together with proper gaskett, all seems well.

Colin4935.

Just a thought, perhaps a recess to hold a kick start return spring??

 



-- Edited by colin4935 on Monday 24th of October 2016 01:44:44 PM

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ttr steve


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More like someone took to it with a sharp object to split the casingcry Not vey clever, but glad you are sorting it.



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Barrelman


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I've just done same to mine trapped the rear brake light switch metal rod between the cases when fitting back together. Tightened bolts and created a 2mm hole in the gap between the cases. I could have cried when I realised what I'd done. Can anyone suggest type of filler to put in and sand flat. Identical problem this.

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mossproof


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Any 2-part epoxy will do, for eg this:

www.bearings-online.co.uk/item/2953/BONDLOC/Bondloc-B2002-Aluminium-Epoxy-Stick-50g.html

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mossproof


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Bondloc B2002 or something similar. I tried posting a link but the website thinks I'm spamming or something. 2 part epoxy with aluminium powder.
Bad luck! At least the mystery is cleared up though.

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