Clutch Cover Crack

A common issue on the Honda Bros is a crack on the top left bolt hole. I have seen this on a few bikes that have come into the garage, although I have only seen it on 650s never on a 400 although it is an identical part.

Crack from the inside.

The crack can be seen here, it appears to initiate from the corner and work outwards. To remove this cover the rear exhaust has to be loosened to allow it to be pulled off, plus the end can and Y-pipe needs to be removed.

 The Y-pipe was a little corroded and the lower pipe was covered in oil, this is from the cracked case.

Once the cover was off it was just a straight swap, I used a new gasket. I had a cover lying around off of an earlier model bros there is a slight difference in covers. The earlier models have an oil feed pipe that goes up from the clutch cover and splits to each cylinder. I used a bolt to blank this hole off.

I cleaned the surrounding frame and mainstand which had been covered in oil.

 Thw new casing and gasket all in place. I put the bike on its side stand when I took the case off but I still lost about half a litre of oil.

I cleaned the pipes with some rag and solvent. I then used high temperature sealant on the femal side of the joint to help with the sealing.

Other than this crack the bike has been faultless, even with regular use and abuse in all weathers.