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I recently replaced my kick starter and must have tweaked my clutch cover because after a long ride today i have a hair line crack running above the water pump housing that is weeping tranny oil. So my two questions are will a clutch cover for an 89 E1 fit my 92 E4 they are coming up as different part numbers. I would preferably just replace the whole cover instead of weld but has anyone had a welded clutch cover hold up ok. I just dont want to have to worry about it.

Thanks,
Ben

I had a friend weld up a cracked clutch cover on my son's old CR80. My friend said he had a hard time welding it because oil kept coming out of the pores of the cast aluminuml and contaminating the weld. The weld still looked pretty good so I put the cover back on the bike but for the last 10 years oil seeps from the weld. Not much, just enough to make dirt stick to it and leave a smudge.

Years ago the rear gearbox on my quad caught a rock and it tore out the drain plug, along with a small crack.

I fixed it with a stick of epoxy putty.

I cleaned the surfaces real well before applying the putty and it has held up since 2004. It doesn't look "pretty", but it also hasn't leaked a drop of oil.

A good TIG welder could probably fix it, but as Brian said, the oil may make welding difficult.

Good luck .

There is a really nice e1 inner case on ebay that i really would rather pick up hopefully someone will know is there is a difference. Thanks for the input on the welding thats what i figured i got a buddy who can tig but its basically the water pump housing soo id rather not chance it last thing i need is for it to blow going down the trail Ran mint for four hours yesterday its my first kdx and i am already hooked

I think the only difference is in the bushing/seal for the water pump shaft. I have a clean extra sitting in my garage if you are interested. I don't think you'll have a problem using any cover from 89 - 94.

Thanks for the offer I actually picked up a full set of right side covers off of an 89 on ebay for cheap. I just ordered all the bearings plus seals, so have to see if they fit, I think the inner oil seal (second one in) is different like you said. Guess ill find out.

Yeah, the seal is different. However, it is recommended when replacing the water pump seal in the 89 to use the newer type seal from the 90+. Lasts longer or something. That's what I used in my 89, and I had no trouble with fitment. Come to think of it, I'm using an 89 clutch cover on a set of 91 cases, since the RH case was cracked when I bought my 89 bike. I bought the 91 case set of fleabay and it came with a right side clutch cover that I did not use. Hence the spare in my garage, lol.