I don't see any reason you could not re-use the seals......I popped in the kickstart seal with my fingers...no biggie...really.

 

Cool! I am really leaning toward welding it but I've never welded before. This new HTS-2000 seems to be the perfect thing for a novice like me. Supposedly can be done with a regular Butane torch. http://www.aluminumrepair.com/video_new.asp I will decide on Tuesday after talking to Larry the Mechanic at my Dealer.

 

wow, that stuff is pretty cool. Somewhere between soldering and welding.

 

Definitely! Look at the page filled with legit testimonials. The only problem is I can't get enough heat from the outside because it's in the Crotch of the oil filter housing. If I can see the crack from the inside when I get it apart, I'll be golden. If not, It's a new cover for my KLX.

 

UPDATE>>>> Took the KLX to my dealer today and showed The Mechanic the crack. He agreed it was a casting defect and they will call Kawasaki to see if they'll cover it even though I'm out of warranty by 2 weeks. Now I get to just wait. I'll post up more info as it comes.

 

It's been 3 weeks+ and I keep calling my dealer and getting told they'll call Kawi but they never do. I guess I'm on my own. Does anyone know for sure if the inner clutch cover is Aluminum? I will weld the Porous section this week as soon as my Materials get here. Frigging casting defect. If I cant weld it from the outside, I'll pop it off and get it from the inside. A simple wadd of Paper towel completely stops and controls the leak so If I can get a good weld it will be a permanent repair. Swapping the cover with a new one will be a pure PITA. Bearings would need to be pressed out & back in to the new case along with new seals etc.. I am told the oil gauge wont survive the swap. Kawi should send me a loaded Inner clutch cover so I can just swap 1 part. I'll call them and bitch one last time.