Scrap primary inner case...

After inspection, the inner case center boss is undamaged.
I'm still speculating that the crack at the front and chain wear at the rear were due to improper assembly.
The foot peg damage to the outer case was probably caused by a different event.

Thanks so much! I had exactly that problem and it turns out I put the spacer the wrong side of the gearbox. whenever there is a 50/50 chance I get it wrong every time. Ho hum... I am hoping it solves a problem that I have aligning the belt. We will see as it goes back together.

Cheers

Bob Z. said:

So how many have had the left footrest nut punch into the outer case?

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I put a gouge in my cover and bent the foot peg with a tip over.
I ordered the new peg and on reassembly I changed it up a bit. I bought a half nut or jam nut. I ran this onto the peg, them screwed it into the footrest support. The peg was left long enough to support the rubber. Then the jam nut tightened up against the footrest. Better than a half inch of the peg ( the thickness of the nut and part of the peg that stood proud ) that was between the footrest and the primary cover, I cut off flush with the support.
This gives more room for the footrest assembly to move before it strikes the cover.

rgirdlestone said:

Whenever there is a 50/50 chance I get it wrong every time.

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As an aquaintance E/E once told me, It's the 50/50/80 rule; if there's a 50/50 chance of something happening, the first try will be wrong 80 percent of the time! It seems to run true with me...

Nathan

It can be welded, ground down and polished to look like better than new. I recently had a cracked primary drain plug boss welded and did most of the finish work myself. Shop charged m $35 for the welding. I had him weld it up solid and I drilled and tapped a new drain hole. Can't tell it from nos except the boss around the plug hole is much more substantial than before. I was trying to remove it by tapping the drain plug with a block of wood from the opposite side and it broke.

Although this thread is very old, I had the same scoring on the tx side of the inner primary, and was wondering how it happened. Good to know DPO must have done it at one point and not me, as when I recently stripped my bike I first noticed it, and the spacer was in its correct position.

My inner primary looks worse than this but still ok. Now it should stay ok using the IWIS chain.

Dereck