Hi

A friend of mine with a 2006 Pro 300 has got cracks in the clutch cover around the kick axle.

1. Is there some way to fix this? Weld? Glue? Something? The cracks are quite large and goes into the hole for the kick axle.

2. I have a clutch cover from a 2002 pro 200 lying around. I know this fits but how about the clutch? As known the 06 uses mineral oil and the 02 brake fluid. Will the 02 clutch pump funktion with mineral oil? Maybe after changing O-rings?

Thanks for any help!

-Jan

Edited June 10, 200818 yr by JanDyb

Hi Jan,

The 02 cover will fit. The slave cylinder of the 02 operates with hydraulic oil but you may be able to change the 2 O ring seals for Mineral oil compatible types. Problem with the 02 cover is that these flex under clutch actuation and don't provide a positive enough clutch feel at the lever. The 03 onwards covers were improved to prevent casing flex.

Best solution really is to replace the cover with a new one. The case is too thin for a weld repair, and quite tricky to weld in the kiskstart shaft bush area.

Bye, PeterB.

Thank You Peter.

I have heard a lot about the 02 model, but this I didn`t knew..

Now the problem is kind of solved because our dealer just got the cover in stock and the price was far from what we expected. Quite cheap actually :-)

Thanks anyway

-Jan

Hi Jan,

The 02 cover will fit. The slave cylinder of the 02 operates with hydraulic oil but you may be able to change the 2 O ring seals for Mineral oil compatible types. Problem with the 02 cover is that these flex under clutch actuation and don't provide a positive enough clutch feel at the lever. The 03 onwards covers were improved to prevent casing flex.

Best solution really is to replace the cover with a new one. The case is too thin for a weld repair, and quite tricky to weld in the kiskstart shaft bush area.

Bye, PeterB.

Peter is right. The 02' differs in that it uses two o-rings rather than an o-ring and seal on the servo cylinder tower and the 02' case is made from Magnesium. The later aluminum ones (03' on up) have reinforcing ribs cast into the inside. Since you will have it apart, it would be a good idea to flush the system and change over to DOT-5 (Silicone) which is compatable with all seals and will give a smoother pull at the lever (up to 20%).

Jon