Happy new year, I wish no one the New Years day present I just got. Working on the DRZ in my garage, woops-down it goes on the hard, cold cement. Snap! goes the clucth lever, CRACK!! goes the side magneto cover as that perverse shift lever makes contact. Drip goes the oil at the same time the tears drip from my eyes. I've heard the stories about these fragile cases cracking, but that was usually during a good day of riding. Beware all!!! Anyway, I am hoping someone out there may have some insight into this. First, anyone have any idea what a replacement mag cover goes for? Has anyone had any luck with JB Weld? How about a good, reasonably priced Suzuki mail-order parts source? And finally, anyone know if the DRZS and DRZE cases would be the same? I guess it's good that this happened during the frigid months, gives me some time to fix and find some way to prevent from future bad luck. Warranty should cover this, I have never seen a case crack so easily. Thanks all and again,watch out. Dont join this club!

I did the same thing a few months ago. I used JB Weld and filled in the crack. I also JB Welded a small semi circular peice of aluminum around the case in the area of the shifter lever contact. It's held up fine to a few thousand miles of abuse. I reccommend buying the side case cover plate that moderator Perry from DRZ400@egroups.com builds. You can get them from Baja Designs. You have to use the Baja Designs skidplate and this plate bolts up to it. www.bajadesigns.com

btw, i wouldnt bother trying to locate that ignition side case, it costs around $275.00 U.S. Also, why bother when the JB Weld does the job well.

Outlaw Biker

I got a better story, mine has broke on both sides from falling over,  and my fix has also held for hundreds of miles and on other fall overs.
I used JB weld but was thinking what I could put there to spread the presure out if it falls again and came up with this.  I JB welded a quarter on the case side, first a layer of JB weld on the crack then the quarter and some more weld.  Holds great and never leaked a bit, don't look stock but don't leak either.

After I ran my E a while I noticed that the shifter has a very sharp edge where it would contact the mag cover... file that baby down so when it is pushed into the cover a flat section makes contact.  Tell all DRZ owners about this.  Its only a matter of time before we all crack that cover.  U

I just joined the club this past weekend.    After about 4 hours of riding at the track, my last lap resulted in oil spewage all over my bike and me.  Drove straight to the dealer and demanded satisfaction!  They reluctantly agreed that it would be covered under warranty.

Let your dealership know there is a problem!  Let Suzuki know there is a problem!  I've ridden my old DR350 much harder and have never had a problem.

Hey U, after reading your post I went out to the shed to check my shift lever on the Noble Yellow Beast. You sure have this one pegged right! The sharp corner on the shift lever is definitely a menace to the case. Thanks for the heads up.

Pretty spooky when OE parts cost more than carbon fiber.  Checkout DSP http://www.dspracing.com/  and try not to smile when you tell your wife how much you are SAVING by getting carbon fiber replacements.

I guess this is a common thing...I had my bike for 2 days when this happened... replaced the lever, metal epoxied the case and lowered the shift lever one notch so it is now impossible for it to hit the case. I haven't tried to shift with it yet, but I don't expect a problem. I have also "dremeled" the sharp edge of the shifter. Are the carbon covers really better and more solid??

Hey all - Thanks everybody that replied. Based on the situaation, here,s what I'm gonna do. First, see if my dealer will agree to warranty the cover (thanks CSL). I have found out that a replacement is around $150 without any kind of discount. Not too bad I guess. If my dealer cant or wont warranty it, maybe he can give a break on the price. I have also found that DSP does not make this part for any of the DRZ's, they never have. If they only knew the demand that exists. E-Line may consider making one, but they will need a good one to make a mold. I'd love to see a carbon gaurd made for this specific problem. JB weld is still possible, but the crack is kinda nasty, and I do not want to be 70 miles into an enduro and see a shiny left boot! Definately gonna file down that shift.
Again, thanks all and pass the warning.

Howdy All,
Thanks for the heads up on the shift lever. Dead on, on that one. Going to put it on the grinder tonight. I was surfing around DSP's web page last week and I am pretty sure I saw CF case covers for the DRZ? I think I have seen them in White Bros. catalog as well. Has anyone seen or heard anything from Suzuki on this weakness?

P.S
DSP on line catalog shows active part #s for DRZ 400 Carbon Clutch Cover (SCC-DRZ400  $199.99) and Carbon Ignition Cover (SIC-DRZ400  $199.99).

TBuck

[This message has been edited by TBuck (edited 01-05-2001).]

[This message has been edited by TBuck (edited 01-05-2001).]

My fix - Get your old cover welded (not JB) for about $30, buy a new cover and hang it on the wall, never have problem again.

Seems like most of you guys are talking about engine case "covers", whereas my engine case failure was in the actual engine case itself.  A thin hairline fracture tucked up in behind the counter-sprocket.  (Note: I was not riding it very hard when the failure occurred).  The covers that are sold at DSP would not help my situation.  I also posted over on dirtrider.net , but no one seems to care that this is a problem.  Only one other guy stated that he had an identical problem as mine (up in behind the counter-sprocket).  This really seems to be a design flaw with Suzuki and has certainly detracted from my love of the bike.

  The YZ426 is looking better and better...

Did anyone notice that in the cycleworld update their DRZ400 also broke one of its covers

Shookster,
Where is that article?  I didn't see it in "Thumperfest".

It was in the "long term update" on the DRZ and they said that a skid plate probably would have prevented it.

CSL, will you have the opportunity to examine the cracked case after it is taken apart to see if there is an obvious cause for failure?  If you get a chance, let us know what you find.  Thanks!

Yep, just talked to them today.  I will take my camera in and get pictures to post as well.  Man am I glad it's covered under warranty.  12 hours labor, total engine reassembly, etc....