Chinese Side Cover! :/

[Bluey27]

Hey guys!

I haven't really had much of an opportunity to post here before but I can't say how useful this place has been while rebuilding my 3EN2 :3



2 and a half years in the making!

But! On the final hurdle I have encountered an issue - nothing that's totally stopped me but something that had me wondering...

I had to replace the Starter Motor/Crank gear cover with a Chinese replica, I got it in and it looked the business!
The issue I have however, is that if I fully torque all the bolts it jams the Starter Motor! Literally it will not crank at all, but if I back the top two/three bolts back just a 1/4 turn it will crank properly.

Has anyone had this issue? Any advice on this?

[snydes]

Hey guys!

I haven't really had much of an opportunity to post here before but I can't say how useful this place has been while rebuilding my 3EN2 :3



2 and a half years in the making!

But! On the final hurdle I have encountered an issue - nothing that's totally stopped me but something that had me wondering...

I had to replace the Starter Motor/Crank gear cover with a Chinese replica, I got it in and it looked the business!
The issue I have however, is that if I fully torque all the bolts it jams the Starter Motor! Literally it will not crank at all, but if I back the top two/three bolts back just a 1/4 turn it will crank properly.

Has anyone had this issue? Any advice on this?

I had to rebuild my starter a little bit ago and I used a kit of canadasmotorcycle.CA but I never had to replace the cap or bearings. I'm not sure if those bolts are maybe shorter than he originals?

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[willandrip]

I have fitted a few HD covers to FZR 400s from different Canadian manufactures and had no problems but
have not tried a Chinese replacement.

They are not known for their engineering tolerances in a positive light.

It would not need much of a discrepancy to jam the starter motor.

I did have one problem of a starter motor jamming with one particular cover when I first started with FZR 400/600s
but it was a fault in the starter internally that was allowing the commutator to move and jam against the brush housing.

Have you tried using multiple gaskets to pack the casing off the crankcase ?
Also if the locating dowels are no longer present it takes a bit trial and error to align the casing correctly.

[Bluey27]

I have fitted a few HD covers to FZR 400s from different Canadian manufactures and had no problems but
have not tried a Chinese replacement.

They are not known for their engineering tolerances in a positive light.

It would not need much of a discrepancy to jam the starter motor.

I did have one problem of a starter motor jamming with one particular cover when I first started with FZR 400/600s
but it was a fault in the starter internally that was allowing the commutator to move and jam against the brush housing.

Have you tried using multiple gaskets to pack the casing off the crankcase ?
Also if the locating dowels are no longer present it takes a bit trial and error to align the casing correctly.

That was kind of what I was thinking - tolerance likely aren't up to spec but I couldn't afford the NRC cases

It's a good idea packing the gasket out. I have some spare so I might try that when I service it very soon

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[willandrip]

Those NRC used to be available quite cheap at one time.
I know what you mean about their cost now.

We first saw the Chinese casings in the UK about 2 or 3 years ago but could not get any feedback from purchasers.

If you use the sidestand...there is very little oil loss, if any at all, when you remove the casing.

I have repaired a lot of the side casings on these with reasonable results after being tutored by a UK forum member who excels at it.

[Evilchicken0]

If the casing jams the starter then there should be some marks on the inside of the casing. Have a look, and get the Dremel out. If you cant find where it touches then put some paint on the inside bolt it up and try, you could also back the bolts out a touch until the starter just about turns to get more of a scratch.
If you only have a 1/4 turn tolerance then it should only foul by 1/4mm ...