Unfortunate hole in clutch cover - options?

[blue.raccoon]

I discovered (following a slight oil leak) that my crank end bolt seems to have made an unwelcome appearance through the clutch cover on my mk 3 as per the below.





Christ knows how that has happened - I am sure I torqued it up properly when I rebuilt it a short time ago but it is far from beyond the realms that it is not as a result of my own ineptitude.

Anyway, was wondering if having the clutch cover repaired/welded is an option and if so what metal its made of so I can maybe hawk it round some welders if necessary.

Cheers

[knackeredMk1]

Never seen that before .

I've got a clutch cover that you can have but you need to find out why you have that hole before you do anything. Did you put an extra spacer in there or just not tighten the bolt and left the key to take the strain .

[blue.raccoon]

Yes, not sure - I remember the woodruff key did seem to slide around a bit in the slot so am wondering if that has created my difficulty now.

I think I will try and get hold of a replacement and then carefully take it apart and see what can be found. Ordering a new key is prob on the menu as well.

Cheers for the response - will PM about the cover.

[back off road]

,thats a new one on me,a new case seems the best bet but there is always the 2p and chemical metal trick

[twistednuts]

Think its made of magnesium alloy, back off roads trick is probably the easiest

[blue.raccoon]

Big thanks to Knackered for sorting me out with a clutch cover on this. Very well packed and sent quickly - much appreciated. V happy indeed.

It may well be I used the wrong woodruff key when putting this engine back together which would perhaps explain the last gear on the crank spinning and the bolt coming undone. I shall investigate further tomorrow now I have got the correct key from LT.

Cheers for the help.

[blue.raccoon]

OK - so I am having problems with this.

I have a new woodruff key whuch is deffo the right one and it is the same size as the old one. It just doesn't seem long enough as the slot in the clutch side of the crankshaft seems too long. As such it is sliding around in the slot and has no doubt allowed the very end gear and bolt to spin free hence my hole.



I have looked at the parts manual I downloaded and I can't see any parts I seem to be missing. Basically I have the large spacer that goes on the crank side, the three crank end gears with slots in for the key, a washer and then the bolt but none of this stops the key sliding further into the crank slot. Any ideas what I am doing wrong?

Cheers

[knackeredMk1]

I can't see anything you are doing wrong . Make sure the key is right across all three 'gear' slots before you put the washer on and bolt it up. Also is the washer 'sided' the LT manual suggests it is .

If everything is correct do up to the right torque and ...............

[blue.raccoon]

Ok - thanks Steve.

I reckon I might have worked part of this out. Putting the large collar back on the crankshaft last night and then lining up the end gears it looks like the smallest end gear is not quite flush with the end of the shaft and is in fact sticking out a few mm which I'm sure can't be right.

When I rebuilt it I remember putting an o ring on the clutch side of the crank shaft which was what the parts manual I gave seemed to suggest was needed but looking at the LT manual it doesnt seem to be there. I am wondering if this is causing the collar to then stick out a bit or possibly the collar only goes on one way and I've got that wrong?

[knackeredMk1]

I believe the o-ring is for the Mk1 only. It is not in the Mk2 or 3 parts manual . Suprisingly the Mk1 is more sophisticated than the others in that there is a cush drive onto the primary drive gear and oil lubrication pathways through the crank to this. Mk2/3 just use a collar to replace this.

[blue.raccoon]

Pretty sure the o-ring should actually be there - LT supplied it within the seal kit for my bike and there is a groove for it in the crank. I reckon I just didn't torque it up properly but I've done it as per the LT manual now.

Got a new problem now in that I can't get my replacement clutch cover on as it look as though it differs very slightly from the mk 3 one I removed - there is a sort of milled out area on the mk 3 one for the crank end bolt whereas the replacement one I have is mising this and has a sort of metal stilt that sticks out and touches the end bolt. As such, there is insufficient clearance to get it on properly.

I am now thinking laterally/bodgetastically. I could:
a) Try and dremel the bit on the replacement cover off and see if this gives enough clearance although knowing my luck it won't
b) Fix the old cover with some JB Weld or the like or
c) Wait for a clutch cover to come up on the Bay

Decisions, decisions!

[knackeredMk1]

I've had a look through the bits I've got. I've got a Mk1 clutch cover and I think I can see what you mean about a 'post'. I think it's an oil spout to return oil splashed about onto the end of the crank. I've also taken the clutch cover of a Mk3 engine I'm working on and it is different.

I think what I have done is send you a Mk2 clutch cover . The Mk1 & 2 have a nut that locks onto the crank whereas the Mk3 has a bolt. Thus the Mk3 crank assembly is longer.

If you can take a photo then this will confirm and I will send you a replacement cover if so. You can return the other cover if you wish to but don't feel obliged to as it was my mistake .

[blue.raccoon]

Cheers for the response Steve - have PM'd you.

[knackeredMk1]

I'll send a replacement tomorrow .

[blue.raccoon]

You, Sir, are a star.

Thanks