Broken crankcase cover, insides ok?

[iceaway]

Today I managed to drive my bike into a heavy flower pot at the gas station (doh!). Besides scratching the side cowling I also made a dent in the crankcase cover. A few drops of oil came out after the incident, but I drove the bike the last few hundred meters home. The rain has been pouring down, and as I don't have a garage I haven't had the opportunity to take it apart yet. Judging from the pics below, do you reckon it's just the cover that has taken a beating, or could the internals be affected as well?

 

[kaitsdad]

That would be the stator cover, if I'm looking at the pics correctly.

It's obviously leaking- but if you had damaged the rotor inside, you would know it by now.

I would suggest a new stator cover - you'll have to remove the existing stator, install into the new cover, and replace. Don't forget to order a new gasket, as well as new stator bolts.

Good luck.

 

[FJRay]

Thats the stator side so I would want to be real sure that rotating things aren't contacting what they shouldn't.

 

[wfooshee]

Change the oil. Now.

The oil behind that is not under pressure, just spray and splash, so if it can leak out, rain could leak in, giving you water in the crankcase.

Changing the cover is not that hard, but that magnet under there is STRONG. It comes off suddenly once you break the field, and it will eat fingers if you have any underneath it while sliding it on.

You'll also have to migrate your stator coil to the new cover, and those bolts are very very very tight. You'll want an impact wrench and a bit that fits the screws EXACTLY.

 

[mcatrophy]

At worst it might have bent a bit of the stator, you won't know until you've had it off.

Picture below shows there is some clearance, I think you've probably get away with it.

(Click on image for larger view)



(The picture shows the intermediate gearwheel on back-to-front, placed there as somewhere safe to keep it.)

If it had touched the rotor, I'd think you would hear it, and from what I remember, it doesn't get as far out as your damage. Mind you, it was over 4 years ago.

Undoing the stator screws was a bit tough, you might need an impact driver. I didn't (I don't have access to one), it took a lot of persuasion to undo those three screws.

No need to drain oil if you can see the oil level in the site glass (though a little residual will dribble out). [edit] Unless you're worried about rain contamination as per wfooshee above.[/edit]



I see wfooshee has posted just before me, he's right about the strong magnet. If you leave the stator wires connected (as I did), make sure you don't break them as the magnet finally lets go.

 

[Canadian FJR]

Please post up the cost of a new stator cover when you find out.

Thanks,

Canadian FJR

 

[iceaway]

Thanks for all the advice! Since I don't have access to a garage at the moment I'm leaning towards letting a workshop do it for me. As for the cost of a stator cover it's 109 EUR + shipping and tax. Stator cover + gasket including tax and shipping is about 170 EUR.

 

[rickysnickers]

I have a used stator cover that is scratched. If you are interested, I can see how much the post office would cost to ship it. With the scratch in it, I was looking for $40 US plus the shipping.

Rick

 

[RaYzerman19]

If you don't mind the cosmetics, and are wanting a quick fix, you could clean up the area down to bare metal, apply some epoxy to keep the oil in and the rain out. Assumption is there is no internal damage....... hope all goes well with your fix.

 

[iceaway]

I have a used stator cover that is scratched. If you are interested, I can see how much the post office would cost to ship it. With the scratch in it, I was looking for $40 US plus the shipping.

Rick

That is very nice of you! I'll let you know if I decide to do it on my own (i.e. workshop wants ridiculous amounts of money).

 

[Auburn]

I have a used stator cover that is scratched. If you are interested, I can see how much the post office would cost to ship it. With the scratch in it, I was looking for $40 US plus the shipping.

Rick

That is very nice of you! I'll let you know if I decide to do it on my own (i.e. workshop wants ridiculous amounts of money).

It's just a few bolts and a gasket. Take your time, follow the service manual and do it. You'll be glad you did. Make sure you have the correct allen head socket and use a good torque wrench. I seriously doubt you did any damage to the stator, you would have known it on the way home. It would have been grinding. You will be able to tell when you take the cover off, you will see damage to the varnish on the stator if it rubbed.

 

[iceaway]

I've seen many people strongly recommending using an impact wrench for removing the stator bolts, but unfortunately I do not have access to one. My torque wrench is also only graded from 19-110 Nm (if I remember correctly the bolts I have to deal with require 10(12?) and 130 Nm). This along with the fact that the bike is stuck outside my apartment on the street, makes me a bit hesitant to take on the job myself. Especially since my previous endeavors into the DIY-world has not always been very successful

 

[mcatrophy]

I've seen many people strongly recommending using an impact wrench for removing the stator bolts, but unfortunately I do not have access to one. My torque wrench is also only graded from 19-110 Nm (if I remember correctly the bolts I have to deal with require 10(12?) and 130 Nm). This along with the fact that the bike is stuck outside my apartment on the street, makes me a bit hesitant to take on the job myself. Especially since my previous endeavors into the DIY-world has not always been very successful

When I did mine I put a chair beside the bike to act as a workbench, took off the cover, laid it on the chair (with a cloth to prevent scratches on the new cover).

Put a well fitting allen key into one of the stator screws, then used a hammer to tap it to start it to undo. Acts like a poor man's impact wrench.

If you do this, hold the key pushing in the "undo" direction as you tap it, that way you reduce any movement of the key within the screw head that would cause damage. Couple of sharp taps should be enough to start it.

Doing them up, I simple did them tight. Not "megga grunt" tight, just sensibly one hand pulling the key until it didn't want to turn any more.

In the limit, if you can't undo them, you can always replace the cover and take the bike to a shop, all you will have lost is a bit of time. Or even, if you have alternative transport, undo the wire connections (somewhere near the engine?) and take the cover to a shop, have them just undo the screws.

 

[dcarver]

$88.99 at PartShark

 

[iceaway]

Thanks for all the encouragement, I'm really leaning towards doing it myself now. I just want to make sure I order the correct bits. Do I really need the new stator bolts? If so, does anyone know what the part number is? I can't seem to find them in the catalogue, they aren't in the same place as the other bits (looking here)

This is on my list:

Cover. Crankcase 1: 5JW-15411-00 (superseded by 3P61541100 apparently, so I guess I will order that part)

Gasket. Crankcase Cov: 5JW-15451-00

Other than that I will get some gasket remover and loctite, plus the appropriate torx/philips bits. Do I need anything else?

@dcarver: Unfortunately I think that shipping + tax will make the price about the same as if I get it here in Europe. And I suspect the delivery time will be a bit longer as well. Thanks for the tip though!

 

[mcatrophy]

... Do I really need the new stator bolts?...

I re-used my old ones, no problem at all.

 

[SkooterG]

$88.99 at PartShark

Does anyone realize the OP is from Sweden?

 

[rickysnickers]

Yes.

Rick

 

[wheatonFJR]

$88.99 at PartShark

Does anyone realize the OP is from Sweden?

Why? Do you have anything against the Swedes?

Yes, it's great to have the international contingent here...