Sometimes you gotta run with it when the inspiration hits you. I made this up Saturday afternoon after getting the bug. This is my second try at a case saver. I ended up not liking the first one I made a couple years ago.

Running the stock cover in many of the heavy clay mud places I ride. The mud gets jammed in there, and starts coming out the holes in the plastic cover like play-doh.

First version is laying on the left. Cardboard template for the new one. Worn out diamond grinding wheel provides the raw aluminum stock. TNC will call me cheap again.



Bandsaw cut out.


Beltsander cleans up the saw cut.


Bandsaw again for the notch. Files to clean up the cut to an even thickness (within .005).


My handy $400+ "extra crankcase" for easy fit checks.






A little wet sanding


A little polish. ( I may take it back to the sanded finish, not sure which I like best. )


On the bike.



Dan

 

Pictures of my first one. I don't like the pinch point this one creates. You could really get a rock jammed in there.





The prototype I made has taken a few hits.


https://www.kawasakiforums.com/forum...-models-38813/

 

Cheap or not, dan, that's some nice work there. It's looks effective, well contoured for the application, and super strong. Good stuff.

 

Nice work, Dan.

 

Nice work Dan; you probably saved ~$50 compared to some of the fancy CNC anodized case savers I have seen.
In the few instances I have seen chains come off, damage has ranged from nothing to catastrophic. I know it's pretty unpredictable to know what a broken chain is going to do once it's loose, but the common denominator in the instances I saw with no damage was the presence of a case saver. I wouldn't ride without one.

 

What's the white thing you have stuck to the engine case? Looks kind of like the DRZ engine covers.

 

That there is some nice work. What size front sprocket is that?

 

i like that sketch too!

EMS, it says 14T on his drawing.

 

Thanks guys. We'll see how it works out. I'm thinking the leading edge of it will take a bit of a beating from the chain and whatever else gets drug in there.
The sprocket on the bike is a 14t.
Mike the thing on the stator cover is a guard I made up.https://www.kawasakiforums.com/forum...otector-39780/ Probably similar to the drz one you mention. One of my buddies has something like that on his KTM. The used stator cover I got off eBay to replace mine had a good gouge in it, so this will give me a little extra insurance.
Dan

 

How much and when can we expect delivery.