A Time Bomb?

Even before I brought the bike, I knew there was a dent on the clutch case where the brake pedal made a contact but I didn't know it was this bad until I opened the case.

Here, you can see the dent on the outside. The PO attempted to spray paint it silver but I caught it but thought nothing of it.



In the next photo, you can see the other side, inside the case. So far, nothing leaks YET. The crack is about an inch long or so.



Now, the question, is how should I remedy this.

a) Ignore it and just ride on.
b) Push the dent out and risk making it worse (aluminum is more brittle).
c) Smear something (epoxy, etc) on it
d) Have it reinforced (weld, etc)

I'm opting for either A or C but I'm concerned about epoxy breaking off and playing havoc with the clutch assembly.

Suggestion?

 

Something similar to this happened to me when I laid down my XS400 and slid sixty feet or so on the right side, put a non-trivial hole in the crankcase. We actually fixed it with some specific crankcase sealant that dries hard but has a little bit of play in it so it doesn't crack under vibration. I'll see if I can dig up what it was, that stuff let me put another 8000km or so on the bike before the electrical system disintegrated on me and it turned into a parts bike

 

This isn't the exact stuff we used, but it should get you on the right track:

ThreeBond Crankcase Sealant/Bond

 

Or you could look for a new cover

 

Thanks Lefty, that gives me an idea. I will just use something similar, probably a silicone-based gasket maker, something that won't hurt the clutch assembly if any of it comes off.

New cover? Not that desperate... yet... Not aiming to have my bike look as good as yours, Alive.

 

This is the stuff that will do the trick.

You'll need a bottle of MAP-Gas.

http://durafix.com/

 

"D" -or- JB WELD!!

 

I'd take it down to a local machine shop and have them TIG that up for you.